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Tuesday, September 4, 2012

TUTORIAL: Repair A Frayed Controller Cable!

We have all, at some point or another, experienced this. Whether it's our own controller that just got worn, a recent eBay or craigslist purchase, or a friend or family members' controller. Time to put away that nasty old Duct tape. No more using electrical tape! Do it the right way...

Xbox Modification, Repair and Tutorials


Start with your controller with the frayed end.
Xbox Modification, Repair and Tutorials

Cut the cable right after that blocky thing (I don't know what else to call it). Get as close as you can using side cutters, or "dikes".
Xbox Modification, Repair and Tutorials

Xbox Modification, Repair and Tutorials

Locate and remove 7 screws. Normally the 7th screw is under a sticker. In this case, the sticker has already been removed.
Xbox Modification, Repair and Tutorials


In this example, you can leave the PCB (Printed Circuit Board) in the lower half of the shell.
Xbox Modification, Repair and Tutorials

Clip the cable on both sides of the boot.
Xbox Modification, Repair and Tutorials

Preparing the boot: You're going to want to remove everything from inside the boot. I used needle nose pliers to pull out the wires and shielding. I used a combination of an x-acto knife and a dremel to remove the original cable shrouding.
Xbox Modification, Repair and Tutorials

Xbox Modification, Repair and Tutorials

Remove the shroud and shielding from the wires attached to the PCB. Cut to size, strip and tin.
Xbox Modification, Repair and Tutorials

Cut your controller cable at a 45° angle and thread it though the boot.
Xbox Modification, Repair and Tutorials

Xbox Modification, Repair and Tutorials

I got a little ahead of myself... sorry.
Pull the boot back, strip and tin the wires. Solder the corresponding wires from the cable to the wires on the BCB. Use heat shrink to seal everything. If you notice in this picture, I used several pieces of heat shrink to make a "stop" that sits right in front of the boot to keep everything from pulling out.
Xbox Modification, Repair and Tutorials

Screw the shell back together and enjoy your newly restored controller!
Xbox Modification, Repair and Tutorials

You can apply this concept to ANY controller for the xbox... not just an s-Type. Doing this WILL shorten your cord by at least 3 inches, but hey, no more "sweet spots", no more sticky duct or electrical tape, no more fighting over the "good" controller.

Enjoy!

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