I am building a custom 47-key keyboard. I have been through close to 30 different designs now and am feeling real close to the one I am going to build.
Here is a 3D view of it (notice the 3 bottom keys are a full key-height down from the others. Now both thumbs have something to do!):

And here is the layout:

If you want to know the specifics of how things are going to work and why I did what I did, go to my blog. Here is a link to its "table of contents" page:
http://tomorrowlabs.blogspot.com/p/buil ... board.html
Thanks, and if you have any feedback, I would love to hear it. Also, if you want any of my vector graphics or 3-D files, let me know. I am also programming an android version of the keyboard so I can learn to use it easier (that's how I learned dvorak. I plan to switch to Colemak for this one, though.)