Thanks for the comments everyone. I already have an external switch board in the works which will be included as part of the kit. As for the USB part, it wouldn't be possible (yet anyway) to do since programming the NOR requires around 50 something points soldering. Leave it with me though as I have a few ideas to work on for now. I'm thinking Atmel or Actel for the cpld as I have a little bit of coding experience with them. I'll keep you all updated!
great work, i'm sure the final product will be more refined. with "external switches" so people don't have to open up the console every time. its early days yet but maybe an all in one dual boot/downgrader too?