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How to Make a Portable Game System

Step 27Making the Controller Buttons

Making the Controller Buttons
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What you need:
Hot glue gun
Some kind of light foam (optional)
4 NES controller A/B buttons
An NES controller D-Pad cross
Plastic card (A gift card works well)
X-Acto knife
A file

With the controller done, you need to make the buttons. For the A, B, Start, and Select buttons you will need 4 NES controller A/B buttons. You are free to use whatever buttons you like, these are just what I wanted to use.

TAKE OFF THE OLD TABS
To start, the tabs on the buttons were too thick. I had planned ahead what thickness of plastic I would use (1/8") and the buttons were almost flush with the acrylic. So, first, I had to break off the tabs. You can use needle-nose pliers for this, but as you can see in picture 2, I quickly learned that this wasn't a good idea. So, I used a combination of an X-Acto knife and a file for the rest.

ADDING PLASTIC CARD SO THE BUTTONS DONT FALL OUT
Picture 3 shows all the buttons correctly prepared. (Except for the one on the far left. ;P )
Now you're thinking, "How are the buttons going to stay in the acrylic? They'll fall right out!" Not to worry, I planned for that. Get some kind of thin plastic or other rigid material. I used an old Dell gift card that had $1.78 left on it. Cut out small strips, and hot glue them to the bottom of the buttons. Now the buttons won't fall out. :D

PADDING
Since I didn't get to use those "mushy" tact switches in my controller, I wanted to add some padding so the buttons could be pressed a bit without actually pressing the tact switch. I found an old foam sheet that goes on top of your mattress, and cut some from that. I glued it to the bottom of the buttons.

Glue another piece of foam to the D-Pad, and you're done with the buttons!
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Author:1up(ModRetro)
Sometimes my Instructables are few and far between, but I try to make them as well as I can. Hopefully you can be inspired or helped by the content in them!