So what I need to do, is figure out a way for the plug and the port to make contact.
I have printed some female/male controller plugs/ports, and the way I got them to work was pretty hackish.
I had to break my pins off and then inserted these metal things into the plug, while it works, its hard to direct it into the slot, and they can bend easily. This was my result from that.
I made another print, this time seperatly printing the pins because there was too much oozing, and I would have to spend hours cleaning it up so it would fit properly. Now that I have a way to cleanly make them, and have them fit perfectly, I just need to figure out how to line the inside of the plastic pin with metal, so it will contact the metal pins on the other side.
Here is a picture of what it has to plug into, I was surprised that there was quite a few people who have never seen a nes controller on one of the last posts I had made.
You are discovering why plugs are really really hard to do properly. Why we don't get a new type of USB plug every single month. It literally takes years to design a new plug.
I would start with working out how big the actual pins are that you're plugging into. Then I would find something in the MOLEX or TE Connectivity catalogs which has pins that size. Something where the female pins are removable from their housing. Buy a pack of 100 pins for just a few bucks.
You will find that those pins have little tiny barbs on the side which hold them in place in the housing. Then print something which fits that back end of the pin. Crimp the pins to the wires and slide them into your custom housing.
Can you really not just buy these plugs somewhere?
I've been trying to find pins to buy for a while now, google and amazon just give me the kind of pins you put on a shirt, so thanks I definitely will check out those catalogs. Its exactly what I needed.
As for sizing them I really don't know how I would, they are in the system, or in this case the 4 player splitter. But if I were to guess I would say 0.6mm. I don't think the ones I'm using are barbed though, its very easy to pull it out of the socket. Just seems like a bare pin, and then what I'm trying to make right now, the original is just a thin sleeve.
And yes, I can buy these plugs on ebay, well kind of. I can buy extension cords which come with female and male end for around $2 per cord. They take over a month to get here though, but I actually did order a few a couple days ago. So in the mean time I thought this would be fun, I did really want to try and make them on my own anyways.
I actually figured out something for now. I took a twist tie, stripped the plastic off, and then heated it up with a lighter, then I stuck it to the inside of the pin. Works pretty good I must say!
Thanks for suggesting those catalogs, you were more help then you probably know.