This instructable will teach you how to construct homemade game controllers for personal games, education aids, or anything you want.

This system uses 4 controllers which send signals to a central hub which holds an Arduino.

It was designed for use with a game called Fraction Smash that my group was developing for a class. Students would enter a fraction using the keypad to re-size their character and then hit the smash button to break through the door if they are the right size.

More info here:
http://pdi-studio5.wp.rpi.edu/fraction-smash/

Parts:

Keypad (3.95)
http://www.sparkfun.com/products/8653

Buttons (1.49)
http://compare.ebay.com/like/120554574811?var=lv

Ethernet Keystones (1.24)
http://www.monoprice.com/products/product.asp?c_id=105&cp_id=10513&cs_id=1051308&p_id=5371&seq=1&format=2

Arduino (29.99)
http://arduino.cc/en/Main/Buy

Breadboard (5.95)
http://www.sparkfun.com/products/137

Wire
Ethernet cables
Super Glue

Step 1: Cut Out Pieces

The first step is to cut out all the pieces to be used. In my design I used a CNC waterjet cutter for all the parts. You could also use a laser cutter for precision parts. If you don't have access to either a waterjet cutter or laser cutter you can cut the parts out of wood by hand. If that is your choice, I would recommend skipping the tabs and just using nails or screws instead.

The .DXF files are attached for automated processes.

All of the CAD files and assemblies can be found here:
http://pdi-studio5.wp.rpi.edu/files/2011/12/Fraction-Smash-CAD.zip

Step 2: Add Wires to Ethernet Keystones

This system uses Ethernet cables for the controllers to communicate with the hub. I used three wires on the Ethernet cable, power, ground, and data, although there is space for up to 8 wires if you need more room.

Keystones are easy to use. Simply place one wire in each slot and then push the plastic cap down on top. It may be too hard to do by hand so I used a pair of pliers to push it down. It is not necessary to strip the wire as the keystone will cut through the insulation for you to make a connection.

Step 3: Circuit

I used the same circuit for the keypad as this intructable:
https://www.instructables.com/id/Arduino-3-wire-Matrix-Keypad/

The green and white wires in the picture go to the keypad.

The only difference is that I added the arcade button (not shown) with a wire from positive through the button and then right to the output bypassing all the resistors.

Step 4: Contruction

I used super glue to attach all the parts together leaving only the top unglued to allow for maintenance.

The keystones can be pressed into the holes with a little force. Same goes for the keypad. Mine was a little tight so I sanded the edges of the plastic with a Dremel to get a better fit.

Next simply attach the arcade button and connect all the wires. The bread board has an adhesive layer on the back so it can stick in place which is very convenient. The placement of the breadboard and the orientation of the button are critical so that everything fits properly. I designed these to be as small as possible so there is not much extra room.

Step 5: Construction (cont'd)

The hub follows the same process as before.

I added a piece from a breadboard for the power and ground wires and the 4 data lines go into 4 separate analog inputs on the Arduino.

Step 6:

Now simply pop the front plates on and connect the Ethernet cables.

For more info on the project I used this for see here:
http://pdi-studio5.wp.rpi.edu/fraction-smash/

You can also find code there to use.

Thanks!