David Randolph from G4TV’s Attack of the Show has a great how-to on making a micro-sized NES controller. Earlier, they made the world’s largest. This little project (pun intended) is pretty easy to do; however, it will require a new skill: PCB (Printed Circuit Board) creation. In volume 02 of MAKE we have Step-by-step instructions for making your own PCBs at home. Link.
Build the world’s smallest Nintendo controller