So, this is a custom controller mod that I am going to give my uncle for Christmas this year.
The problem that I usually run in to with getting him a controller, is that he is exceedingly rough with it, often resulting in the sticks being ground out, broken off, or the controls being funky.

As of current, the project is only in the "Parts" phase, though it should be relatively simple for me to pull off.

Parts:
http://www.ebay.com/itm/111507507426?_trksid=p2060778.m2749.l2649&ssPageName=STRK%3AMEBIDX%3AIT
Wireless PS3 controller.
The fancy paint job aside, this is the basis for the entire project. my goal is to make this last awhile in my uncle's care.

http://www.ebay.com/itm/111459892858?_trksid=p2060778.m2749.l2649&ssPageName=STRK%3AMEBIDX%3AIT
Aluminum thumb sticks.
This is one of the most common things to break, because he grinds it so hard on the sides of the controller, it grinds the stick off.
I'm hoping that Aluminum will be a bit more durable than the standard plastic, thus lasting longer.

http://www.ebay.com/itm/121432032647?_trksid=p2060778.m2749.l2649&ssPageName=STRK%3AMEBIDX%3AIT
Aluminum face buttons.
It actually isn't uncommon for my uncle to hit a button hard enough that it cracks.
Like the sticks, I hope that these are more durable, thus taking more abuse.

http://www.ebay.com/itm/161374133628?_trksid=p2060778.m2749.l2649&ssPageName=STRK%3AMEBIDX%3AIT
Arcade console buttons.
This is going to be part of a minor circuit mod.
I hope to jump L3. and R3, away from the stick controls, and have them operated elsewhere on the controller, and, if successfully, disable the standard L3 and R3. This should help prevent my uncle from grinding the sticks, while trying to press L3 and R3, thus preventing damage to the internal components of the control sticks.

I have no idea if this is even going to help or not. but when I see what my uncle does to controllers, and how fast they break, it makes me want to do SOMETHING to make it last longer, especially if I want it to last longer than the day it's been opened.

if i were you, i'd put the L3 and R3 switches on the back of the controller so that they could be activated with the middle or ring fingers. this is, of course, given that he doesn't squeeze it hard enough that it'd end up wrecking the buttons as it stands.

is the chrome finished controller actually made out of painted metal, or is it plastic? if it's not metal, is it possible for you to obtain a metal casing for the controller?

I'm pretty sure that the chrome finished controller is just painted.
As much as I would love to have a metal frame, I don't think that I'm ever going to find one, unless I forge it myself.

This is an interesting project, as usual. I didn't know it was possible to assemble an (almost) all-metal game controller like this.

http://www.morbidstix.com/metal-ps3-controller-shells/ perhaps more metal than I initially thought was possible.

Edit:
Actually... those may just be paint...

A quick prototype using the shell of a smashed controller.



So far, this seems to be the most ideal location to place the button.

Also, you can see what I am trying to prevent.

And now, the buttons in place on what will become the final product.


These are already wired in, and have been tested.
They work like a charm!

Wow, lookin' great.

Thanks man!

As I noted on MFGG, I have a bit farther to go, with only a few parts remaining.

The Aluminum thumbsticks, (The normal plastic ones are often the first things to break)
The metal face buttons.

Ones I get those installed, I just need to affix all the additional wires permanently, and disable the normal L3 and R3 triggers, thus forcing usage of the replacements

This looks quite nifty indeed. I like the way the camera flash makes the controller look as if it was on fire!