Hello all, I am new here, so I thought I'd like to contribute a little bit.
I had an idea recently which I am going to be working on very soon, I just have to make a decision on one part:
I am going to modify my Xbox 360 controller to use mechanical switches for the A, B, X, Y, buttons instead of the rubber switch.
I need help deciding which switch type to use for this (I am not that familiar with the types). My preference is a lighter switch (ie. low actuation force) but with a tactile/clicky feel to it. It also has to be small!
Here is a screenshot of a CAD drawing of the controller's board. White = button terminals. Red = Switch size
The Cherry MX Blue switches (my favorite) measure 15.6mm X 15.6mm which does not fit. You can see that it overlaps
Here is a CAD drawing of just any old tact switches from RadioShack. These are "SPST 12VDC/50mA 5.0mm High Tact Switch". The red extension on the top is a representation of the "B" button on the Xbox Controller.
Here is the link for that switch: http://www.radioshack.com/product/index.jsp?productId=3060978&filterName=Price&filterValue=under+%243.99
I can include some other measurements if you would like. Thus far I only have the concept, measurements, and various CAD drawings. I can design a new switch for you all to view and comment on as far as how functional it will be.
[EDIT] In my research, I found out that the Razer Onza has mechanical buttons, however this will be a little bit of a different thing. With a type of keyboard switch (granted I can find one) it will have a smooth feel, as well as a sort of "travel" to it. It also aims to be cheaper, and a simple modification to a controller that you already own.