Things You'll Need
Instructions
Casing
Cut your wood into appropriate sections. You are essentially building a large, flat box. Suggested dimensions are two 16-inch by 10-inch planks, two 16-inch by 3-inch planks, and two 8 3/4-inch by 3-inch planks. If you have no experience with a saw you can ask a hardware store to cut these pieces of wood for you.
Line up the wood and drill holes for your screws.
Sand the wood. Run the sander with the grain rather than sideways to avoid scratch marks. Focus on corners and any rough parts of the wood.
Apply one coat of varnish. Wait for this coat to dry then apply another coat of varnish.
Drill holes on the front part of your controller in accordance with the control pad. A typical layout has the joystick 4 inches from the left most buttons with each button about 1.5 inches apart from center to center. A typical joystick has eight buttons. Six of these buttons are controls and two are menu buttons---typically, select and start.
Putting Everything Together
Screw the buttons and joystick in the holes you created.
Make a ground wire to connect with all the smaller switches. Attach a shorter wire to connect the joyustick with itself.
Connect the wire to the copper surfaces of the circuit board of the joypad.
Make a small groove for the main wire to run out of the joystick. This will be the wire that connects the joystick to the computer of console and should come from the original joy pad controller.