A collection of some of the functional Nintendo controller coffee tables I have built. All tables were built by hand without any CNC machinery.
Step 1: Prototyping the MDF Painted Version
I drew up the table in AutoCAD at x10 scale from the original. The first prototype was made out of MDF. I used 3/4 inch for the shell and 1/8 inch for the raised portions. The button mounts used bolts with springs to give it the bounce. I designed the buttons so you can adjust the bolts to increase or decrease the compression of the springs, giving the buttons more or less of a "bounce" when pressed.
For painting, I went to the paint store and they matched they colours on an orginal controller. I use a small gravity feed spray gun to apply the paint. After all the paint is on, I then spray it with 50 degree conversion varnish to make it shiny and durable.
To paint the lettering I got a vinyl sticker which I placed and sprayed overtop.
Step 2: D-Pad
Making of the D-Pad. I made a jig to use with an overhead router, or in this case a pin router attachment.
Step 3: Wiring.
Picture of the final wiring. I used an original NES controller which I took apart and re-wired it to all the buttons.