Here’s my latest stick, using Sanwa parts and walnut bentwood to. I won’t get into details about the box itself and how to bend wood.
I wanted to make a simple but elegant design with a minimal case. The draw back is minimal interior space to work with, so excuse the wire mess. The inside:
One thing I didn’t take the picture is the stick itself and how it mounts to the box. You’ll notice I don’t have the metal mounting plate. I removed that and mounted the stick using the metal plate’s mount location, which you can barely see the screw visible under the dust washer. I’ll be making a larger dust washer to completely hide the mounting screw. It’s the most simple way to have a hidden mounts for your stick.
Charge & Play / USB Port
I bought a Plug&Play clone cable (a few bucks off ebay), took the shell off to access the PCB. Inside you will find 4 wires that goes to the USB. You basically plug the Plug&Play PCB to the joystick PCB, then cur off the 4 wires to a USB female port. Mount the USB female to the case (I used a dollar store USB 4 port hub for parts for the port connection and the outer casing), so all you need to do is plug a USB cable from the stick to your PC or xbox to recharge.
**Battery Relocation (Standard & Rechargeable)
I cut off the joystick shell that enclosed the batteries so I’ll have a place to put the batteries into. If your case is large enough you can remount this section back to the PCB and call it done. If you want to relocated the battery location, you’ll need to extend 2 groups of wires: the standard and rechargeable battery wires. In red is the standard batteries positive/negative location. I used a spare (broken) joystick for parts, it cut off the battery leads and hot glued it into the plastic battery shell enclosure, then wired them onto the joystick PCB. In Yellow is the 4-wire charge&play battery wires. Using my spare parts PCB, I removed the white battery contacts and hot glued it into the plastic enclosure.
Hope that all makes sense. The only thing I would do (but will get more tricky) is to have some sort of light to indicate it is charging or finished charging. Extending the micro-LEDs is really really hard to do without proper professional soldering tools IMO. A simple solution I’ll be doing is to just drill a small hole at the bottom of my box to act as a window to see the plug&play PCB LED light.