I’ve only recently started paying attention to the GP2x and my first thought was “retro gaming on the go”. I think this is a HUGE draw for many buyers, but the analog stick almost goes completely against the simplified, precise control required for older games.
I’m actually going to hold off on buying this system until a 4-way d-pad is a viable option.
My only argument against an 8-way is that pressing diagonally has been a hit or miss thing with me on many controllers. “I didn’t want to walk into the lava… I pressed LEFT, damn it! NOT DOWN+LEFT! I hate this THING!” Well maybe I don’t get that worked up about it, but honestly the old NES controllers were great.
Maybe the d-pad on the PSX controller is better? It's been so long since I had either.
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Also, I don’t know if the people on these boards have connections to custom parts manufacturing, but I work with a CNC milling machine on fine jewellery ever other day. I’m not offering my services or anything at this point, but designing masters for durable plastic injection doesn’t seem like a far stretch beyond that. I think custom parts manufacturing is not as inaccessible as some people may think.
As far as a new d-pad design goes, the ultimate answer would most likely be to use proven, existing d-pads (NES?) and make a custom mount to secure the directional button(s) that plugs precisely into the existing GP2x hole. From an esthetics (and control) point of view, it’s the best answer.
What are the dimensions of the hole? Just curious.
Its diameter is 7.8mm (0.3 inch).
Then again, first things first… get the thing working properly and then worry about the BLING! Good luck on your project, Radek.