Just thought you might be interested in the XBox 360 Arcade Controller I built recently. It uses a painted original XBox 360 case, wired controller, arcade parts and a few other assortments. All of the buttons on the 360 controller are used and the analog
thumb sticks have also been retained. Some of the more unusual and interesting features include LED rumble, functional front USB ports (USB 2.0 hub soldered inside) and the original power button repurposed as the XBox guide button.
The red shell used for this project came from a RROD console lol That being said, the shell of an XBox 360 is plenty strong enough and its played well so far. It was the innards of the original 360 that was the issue :P
Cheers! Compared to a standard controller it's definitely beefcake lol Compared to most arcade controllers it's not too bad. Might not hurt to carry it around the house for a while and get some beefy Popeye forearms though :D