Main problem with your solutions is that it isn't adressing major issue of gp2x's stick. The orthogonal diections register at 25 degress each and only "25" is way too less. Because of it up/down/left/right movements are sometimes hard to register. Making the hat more selective you'd prevent some of mistakes with diagonals but it will not make hitting othogonals easier. This is the problem with this stick and fastest fix would be rotating it by 45 degress (as sugested by DaveC).
Rotating 45 deg then adding a shim under the control hat to reduce dead zone would be the best I think. If we (Craig) can accomplish the almost insurmountable task of getting GPH to actually listen to us the hard part would be done (rotation). Then we would just have to shim it and we would have a useable stick.
In the "neat ideas" forum, there's a Dpad hack thread that's discussed a carrier board for a complete replacement of the stick, but it may apply as well here. The problem is finding someone with the balls to try it. I'm considering it.
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