Need Racketboy's expertise on a Dual Shock franken-mod.

[vlame]

1/16 then lol.

[Hobie-wan]

Actually I'd say use the 3/32. Gimme a sec to hack together a picture explaining why. Actually guess don't need a picture. The 1/16 is about the same diameter as the threaded part of the screw. You don't want to try and drill the whole screw out because you will end up making the plastic hole wider, then you'll have trouble making another screw stay in there. You only want to drill off the head and stop before you would hit the plastic. That way the head is all drilled off or you get a piece that comes loose and falls out.

Then the shell will come off and there will be a little left of the shaft equal to the thickness of the bit of the now removed shell sticking out of the other part of the shell that you can hopefully remove with needle nose pliers. Since the philips head of the screw is stripped already, it should give you an indention that will keep the drill bit in place as you work. Again, go slowly as possible, a little at a time. Keep stopping to check if the head is gone or a piece will fall out.

[Lodestar]

Second paragraph was kind of confusing, but I get the gist of what you're saying. Drill the head off the stripped screw, then pull out the rest with pliers? I don't know what you mean about hitting the plastic though, if I drill past the head, wouldn't I just be digging further into the shaft of the screw? Or are you saying I should drill all the way until the very end, but not all the way, and then pull out the tiny remnant with pliers? That way I won't rend the screw hole to shit.

[Hobie-wan]

Ok, let me try this again.

Drill the head and ONLY the head with the 3/32 bit. Go very slow, keep checking. Do not keep drilling into the plastic. As soon as you reach the bottom of the screw head and it is all filings or a little hoop falls out, you're done with that screw. With no head attached, the shaft of the screw will still be in the bottom half of the shell, but the shell should open. Then there will be a little stub of the shaft sticking up as tall as the thickness of the plastic that you did not drill through. Hopefully you can unscrew this bit with needlenose pliers so that you'd be able to put another screw in.

So you end up with something like this after drilling the screw head off from the top and pulling the shell halves apart.

[Lodestar]

Alright, thanks for the clarification, that makes sense.

[Lodestar]

Update: I finally was able to get the controller open. Couldn't swap much, only the rubber things, because apparently they're two different revisions of the same controller (go figure). After I did that, I used compressed air to clean out the grime/gunk and now it works well again. Thanks for all the help people.

[vlame]

how different did the rubber things look?

[Hobie-wan]

Yeah, there are tons of revisions of controllers. I have personally seen at least 4 or 5 versions of Genesis and NES controllers that are a little different on the inside. Some are compatible parts wise, some are not. I have at least 2 or 3 different dual shock controller revisions too.

Anyway, glad you got it fixed.