Cracking the 360 controller open will require a torx-8 security bit, or screwdriver. But for those daring few like myself, you can drill through the holes. It's not elegant, but it is effective. Be careful as drilling to deep or at anything besides a straight down angle throught the screw wil damage the PCB; as you can see I knicked it where the middle screw is below.
You're going to have to forgive the photos from my iPhone. My wife has "liberated" our digital camera and well, I want to get finished with this project.
So when soldering to the 360 controller it would appear the most important thing to do is scrape the black contact material. If you try to solder without scraping the material off, you'll end up with a mess. I learned this through a guide over at Xbox-Scene. To do this I used a leatherman, but patience is key. Being too aggressive, or trying to make a go of this too quickly will most likely mean damaging the contact. Below you can see the A & B buttons scraped clean. While the X, Y, Start, Back, Guide buttons still have the black contact material.
I started soldering with the X button. As you may be able to see that's probably the worst solder contact on the board now. After about two hours of this I would suggest two things. One, cut all of your line, and strip it before you start. It just saves time. Two, buy a third-arm, or soldering arm. It will help you in the long run and as holding a wire, the iron and solder in two hands becomes difficult. Even though you adjust over time.
After getting the buttons I, scraped the D-Pad contacts. I was a little apprehensive about scraping anything more than the contacts on the outside of the buttons.
Not exactly finished. I have to remove the LT & RT plastic hardware before I can solder the shoulder buttons and triggers. Though it took only two hours to do this phase of the project, I found that the smoke being burned off from the solder creates one hell of a headache.
The housing is almost complete. But I have to find some acrylic sheets to protect what will be the art work below the buttons and another sheet for the bottom of the housing. Expect the next update around Wednesday this week as I have a few days off from work.
