The N64 Controller Gets Brass Gears Through 3D Printing

The controller for the Nintendo 64 is a masterpiece of design, and despite being more than two decades old, people are still using this controller competitively. Smash Bros, you know. Those competitive gaming enthusiasts are hard on their controllers, and after decades and tournaments, the analog stick will wear out. Previously, this required a rebuild or simply replacing the entire controller. Now there’s another option: a completely re-engineered analog stick, all made possible thanks to 3D printing.

[Nam Le] is a student at Cal Poly, and as would be expected for a very specific subset engineering students, had to track down new N64 controller every few months. The stick on these controllers wear out, so [Nam] decided to make the most durable joystick that has ever fit inside an N64 controller.

The design of the N64 stick is pretty simple, and exactly what you would expect if you’ve ever opened up an analog joystick. There’s the stick itself, which is connected to gears on the X and Y axes, which are in turn connected to encoders. This entire assembly sits in a bowl. After twenty years, the mating surface between the stick and the gears wear down, and the bowl becomes deformed. The solution here is obviously to engineer something sturdier, and despite what most of the 3D printing community will tell you, ABS and PLA just won’t cut it.

[Nam] re-designed the gears and bowl out of brass using lost-wax casting using 3D printed parts. These brass parts were mated with 3D printed gears and an enclosure for the bowl. The stick is nylon, an important design choice because this is the first part to wear down anyway, and it’s also the easiest part to replicate. Yes, this is designing an analog stick for the strength of materials and Real Engineering™ for those of you keeping track at home.

Right now, the joystick works as intended, and lasts much longer than the stock version. The goal now is to get this stick tournament-legal for some serious Smash time, in the hopes of not replacing controllers every few months.

Add-On Board Brings Xbox 360 Controllers to N64

Many of the games released on the Nintendo 64 have aged remarkably well, in fact a number of them are still considered must-play experiences to this day. But the years have not been so kind to the system’s signature controller. While the N64 arguably defined the console first person shooter (FPS) genre with games like “Goldeneye” and “Perfect Dark”, a modern gamer trying to play these classics with the preposterous combination of analog and digital inputs offered by the N64 controller is unlikely to get very far.

Of course, you could play N64 games in an emulator and use whatever controller you wish. But where’s the challenge in taking the easy way out? [Ryzee119] would much rather take the insanely complex route, and has recently completed work on an add-on board that let’s you use Xbox 360 wireless controllers on Nintendo’s 1996 console. He’s currently prepping schematics and firmware for public release, with the hope that support for additional USB controllers can be added by the community.

Nintendo historians may recall that the N64’s controllers had an expansion port on the bottom where you would connect such accessories as the “Rumble Pak” and “Controller Pak”. The former being an optional force feedback device, and the latter a rather oddly named memory card for early N64 games which didn’t feature cartridge saves. Only “90’s Kids” will recall the struggle of using the “Rumble Pak” when a game required the “Controller Pak” to save progress.

Thankfully [Ryzee119] has solved that problem by adding battery backed storage to his adapter along with some clever code which emulates the “Controller Pak”. Similarly, the “Rumble Pak” is emulated by the Xbox 360 controller’s built-in force feedback and a bit of software trickery. Specific button combinations allow for enabling and disabling the various virtual accessories on the fly.

But the best part of this modification might be how unobtrusive the whole thing is. Not only does it allow you to still use the original controllers and accessories if you wish, but it only requires soldering a handful of wires to the console’s motherboard. Thanks to the surprising amount of dead space inside the system’s case, it’s not even a challenge to fit the board inside. You do need to use the official USB Xbox 360 controller receiver, but even here [Ryzee119] opted to put a USB port on the board so you could just plug the thing in rather than having to cut the connector off and trying to solder it to the board yourself.

It probably won’t come as a surprise that this isn’t the first time [Ryzee119] has fiddled with the internals of a classic Nintendo system. We’ve previously covered his fantastic custom PCB to fit a Raspberry Pi Zero into a GameBoy Advance.

[Thanks to Gartral for the tip.]

N64 Emulated in VR Makes Hyrule go 3D

The Nintendo 64 had some groundbreaking and popular 3D games, and [Avaer Kazmer] felt it was only right to tamper with things just enough to trick an emulator into playing Ocarina of Time in VR, complete with stereoscopic 3D. The result is more than just running an emulator on a simulated screen in virtual reality; the software correctly renders a slightly different perspective of the world of Hyrule to each eye in order to really make the 3D pop in a way the original never could, and make it playable with VR controllers in the process. The VR emulator solution is called Emukit and works best with Exokit, a JavaScript web browser for AR and VR environments for which [Avaer] is a developer.

It turns out that there were a few challenges to work around and a few new problems to solve, not least of which was mapping VR controllers to control an N64 game in a sensible way. One thing that wasn’t avoidable is that the N64’s rendered world may now pop in 3D, but it still springs forth from a rectangular stage. The N64, after all, is still only rendering a world in a TV-screen-sized portion; anything outside that rectangular window doesn’t really exist, and there’s no way around it as long an emulated N64 is running the show. Still, the result is impressive, and a video demo is embedded below where you can see the effect for yourself.

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Printing Nintendo Portables With SLA

Downing] is no stranger to building portable consoles, employing all manner of techniques in the process. However, when it came time to start on this commission, [Downing] decided to take a different tack – employing a Form 2 SLA printer in this Nintendo 64 portable build.

Modifying home consoles to become portables often involves tricks like Frankencasing – hacking together original factory parts such as controllers, cases, and accessories, and using body filler and a lot of sanding to create a template for vacuum moulding, which then results in a seamless final product. It’s possible to get some really impressive results, but it does limit the builder to relying on existing parts.

By using the Form 2, [Downing] was able to take advantage of the SLA printer’s ability to create parts with good surface finish that would normally require a lot of post-print finishing when 3D printed with more common FDM technology. This was particularly useful as it allowed the creation of custom buttons and small parts that “just fit” – normally such parts are made from stock pieces that are then modified.

The build also features a few other cool features – there’s a breakout box which allows the connection of extra controllers, as well as hosting AV out for hooking up to a television. The breakout box connects to the portable over an HDMI cable. It’s a tidy choice – it’s a standard cable that has an abundance of conductors available so you don’t have to be particularly tricky to get 3 controllers and a few analog signals talking over it.

In the end, [Downing] wouldn’t use SLA printing again for the case itself – the process was too slow and expensive. In this respect, FDM may require more work after printing but it still comes out ahead in terms of time and money. But for small custom parts like buttons and structural brackets, the Form 2 is the machine for the job.

Video after the break.

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Hackaday Links: October 23, 2016

It’s the Hack ‘O Lantern edition! First up, Slic3r is about to get awesome. Second, Halloween is just around the corner, and that means a few Hackaday-branded pumpkins are already carved. Here’s a few of them, from [Mike] and [yeltrow]:

The latest edition of PoC||GTFO has been released. Holds Stones From The Ivory Tower, But Only As Ballast (PDF and steganography warning). This edition has a reverse engineering of Atari’s Star Raiders, [Micah Elisabeth Scott]’s recent efforts on USB glitching and Wacom tablets, info on the LoRa PHY, and other good stuff. Thanks go to Pastor Manul Laphroaig.

Oh cool, we can be outraged about something. The Freetronics Experimenters Kit is a neat little Arduino-based ‘Getting Started In Microcontrollers’ kit. This kit was sold by Jaycar. Recently, Jaycar ripped off the kit and sold it under the Duiniotech name. The box was copied, the instruction manual was copied, and there’s a lot of IP being violated here. Can Freetronix do anything? Legally, yes, but it’s not worth it.

[Oscar] broke his phone, but it still works great as an SMD soldering camera/microscope thing.

Pobody’s Nerfect in Australia so here’s a 3D printed didgeridoo. What’s a didgeridoo? It’s an ancient instrument only slightly less annoying than bagpipes. It’s just a tube, really, and easily manufactured on any 3D printer. The real trick is the technique that requires circular breathing. That’s a little harder to master than throwing some Gcode at a printer.

[Chris Downing] is the master of mashed up, condensed, and handheld game consoles. His latest is another N64 portable, and it’s a masterpiece. It incorporates full multiplayer capability, uses an HDMI connector for charging and to connect the external breakout box/battery, and has RCA output for full-size TV gameplay. Of note is the breakout board for the custom N64 chip that puts pads for the memory card and a controller on a tiny board.

Hackaday Links: May 29, 2016

Hackaday has a store‽ Yes, it’s true, and we have a Memorial Day sale going on right now. Get a cool robot had t-shirt, a cool clock, or a GoodFET. Spend money. Consume.

Learn COBOL. Seriously, you should learn COBOL. It’s a fact of nature that every computer-minded person will eventually hear that COBOL developers make bank, and you’ll have job security for the rest of your life. Now look at the Hello World for COBOL. Yes, there’s a reason COBOL devs make bank, and they’re still vastly underpaid. [Folkert] figured a way around this problem: he built a Brainfuck to COBOL compiler. Mainframe programming for the rest of us.

[fbustamante] got his hands on an old GP2X Wiz, one of those ARM-based portable media player/emulator things from a few years ago. This is a complete computer, and like the Pandora, it’ll do everything one of those Raspberry Pi laptops can do. The Wiz doesn’t have a keyboard, so [fbustamante] created his own. He etched his own PC, repurposed a keyboard controller from a USB keyboard, and stole the keycaps from an old Sharp digital organizer.

Speaking of portable consoles, [Element18592] built this incredible Nintendo 64 portable. He’s done an XBox 360 laptop and stuffed a Pi into an old brick Game Boy. This N64 mod is great, uses a 3D printed enclosure, and has truly amazing vinyl graphics.

To the surprise of many, [Photonicinduction] is not dead. The drunk brit with a penchant for high voltage electrics and a very, very confused power company is back making videos again. His latest video is a puzzle. It’s a plastic block with a light bulb socket, a UK power outlet, and a switch. Plug in a light bulb, flip the switch, and it turns on. Plug a blender into the outlet, and that turns on too. No wires, so how is he doing it?

Introduced at CES last January, Monoprice – yes, the same place you get HDMI and Ethernet cables from – has released their $200 3D printer. This one is on our radar and there will be a review, but right away the specs are fantastic for a $200 printer. The build area is 120mm³, it has a heated bed, and appears to be not completely locked down like the DaVinci printers were a few years ago.

Handheld Nintendo 64 Only Plays Ocarina of Time

Introducing the SG-N64 — the Single Game Nintendo 64 Portable Console. You can play any game you want, as long as it’s the Ocarina of Time.

You might be wondering, why would you go to the effort of making a totally awesome portable N64 player, and then limit it to but a single game? Well, the answer is actually quite simple. ocarina-of-time-handheld[Chris] wanted to immortalize his favorite game — the Ocarina of Time. As he puts it, making a SG-N64 “takes the greatness of a timeless classic and preserves it in a body designed solely for the purpose of playing it”.

Inside you’re going to find the motherboard from an original N64, as well as the game cartridge PCB which shed its enclosure and is now hardwired in place. Of course that’s just the start. The real challenge of the build is to add all of the peripherals that are needed: screen, audio, control, and power. He did it, and in a very respectable size considering this was meant to sit in your living room.

Now that is how you show your kids or grand-kids a classic video game. Heck, maybe you can even convince them that’s how all games were sold and played! What’s the fun in being a parent without a bit of trolling?

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