Universal Modern Game Pad w/ USB Passthrough | OSUMGP-RP2040

# Last Updated: 25SEP24

3D printed parts for the OSUMGP-RP2040 by NickGuyver.

https://github.com/NickGuyver/OSUMGP-RP2040

RECOMMENDED SLICER SETTINGS

The orientation of each part is essential to proper fit/function.  Please reference the .3mf with all of the parts properly oriented on a single build plate.  In general, each part has an obviously flat part that should face the build plate.

Materials Tested:  PLA & PLA+
Infill:  Triangles @ 20%
Walls:  3
Supports:  None
Polyholes:  Recommended for all but the Top & Bottom parts
Build Plate:  Smooth.  Textured plates will cause flat edges on buttons to catch on the case holes, and will require a deburring tool.

MATERIALS

This design is very much in its infancy, and is highly subject to change.  Materials used were what I personally had lying around:

4 - M3 x 25mm Machine Screws (2 used for the R1/L1 buttons are optional)
https://a.co/d/4n9KTil

11 - #4 x 3/4 inch Self-Tapping Screws (4 used for the USB passthrough add-on)
https://a.co/d/7w6iwYz

8 - M3 x 8mm Machine Screws (4 screw directly into the PCB standoffs)
https://a.co/d/1v6Fcco

4 - M3 x 5.7mm Brass Heat Set Inserts (Set into the handles)
https://a.co/d/eapX5Pv

2 - M3 x 12mm (For the R2/L2 hinges)
https://a.co/d/2H9HYh2

Additionally, the 3d printed parts and a fully assembled OSUMGP-RP2040 PCB are required.

TOOLS

1. Deburring Tool or Utility/Craft Knife
2. Soldering Iron
3. Long Neck Screw Driver

ASSEMBLY

As an overarching caveat to this entire section:
DO NOT OVERTIGHTEN SCREWS. 
DO NOT OVERTIGHTEN SCREWS. 
DO NOT OVERTIGHTEN SCREWS.

Prepare Parts
1.  Use a deburring tool or utility/craft knife to clean up rough edges and imperfections -- especially the flat edges on the buttons and their corresponding holes on the Upper.
2.  Ensure the holes in the hinged buttons (i.e. R1/L1, R2/L2, R4/L4) are big enough for the screws to move around freely.  They should not be tight-fitting.

Handles Installation
3.  Use a Soldering iron to install (4) heat set inserts into the 4 holes in the Left and Right Handles.  Recommend stopping 1mm before full insertion and using a flat metal object to push it level to the plastic, then allow the plastic to cool to room temperature.
4.  Position Right Handle to Lower so that the holes align with the heat set inserts.
5.  Fasten (2) M3x8mm Machine Screws through the inside of the Lower into the corresponding holes in the Right Handle.
6.  Repeat steps 4-5 for Left Handle.

USB Passthrough PCB Installation
7.  If the passthrough board is being used, feed the cable through the hole in the bottom of the case and secure the PCB to the case with (2) to (4) self-tapping screws.  USB port should be facing away from the case.
8.  Attach the USB Passthrough cover with (3) self-tapping screws.

Hinged Buttons Installation
9.  Hold R4 button in position, feed (1) M3x25mm Machine Screw through the case, then through the button, and fasten it directly into the hole.
10.  Repeat step 9 for L4 button.
11.  Hold R2 button in position and fasten (1) M3x12mm Machine Screw into the case.  It will be a tight squeeze the whole length of the screw, but the R2 button should hinge freely.  If not, then the Lower or the R2 Button may need more post-processing.
12.  Repeat step 11 for L2 Button.

PCB Installation
13.  Hold the USB Passthrough cable along the top of the case.
14.  Orient OSUMGP PCB flat in the case and fasten (4) M3x8mm screws directly into the PCB standoffs.
15.  Plug the USB Passthrough cable into the corresponding connector.
16.  Verify that the R2/L2 and R4/L4 buttons operate correctly.  If the buttons feel stuck, the PCB may be seated at an angle, the pieces may need more post-processing, or there is an issue with the fitment of the screws.

Face Buttons and R1/L1 Installation
17.  Place the Upper face down, and insert all of the face buttons and R1/L1 into their respective slots.
18.  Verify that they move freely in their slot, but not fall out.  If not, then the button may be in the incorrect slot, or more post-processing may be necessary.

Join the Lower and Upper
19.  With the Upper face down, carefully join the Lower by hinging along the lower edge of both parts.  Ensure that the R1/L1 Buttons clear the tactile switches as you join the Lower and Upper.  If they do not join, it is most likely because the tactile switches are catching on the R1/L1 buttons.
20.  Verify that all of the buttons operate correctly, and do not get stuck.  If there are any issues... more post-processing may be necessary, or a component may not be seated properly on the PCB.
21.  Fasten (2) Self-Tapping Screws through the Lower into the two inner holes at the bottom of the Lower.
22.  Fasten (2) Self-Tapping Screws through the Lower into the two inner holes at the top of the Lower.
23.  The two outer holes at the top of the Lower are for the R1/L1 Buttons and use (2) M3x25mm Machine Screws, but I have found that they are unnecessary.  Additionally, if you decide to install the screw, do not overtighten as it will penetrate the Upper.  These holes will likely be removed in an update to the design.

Congratulations!  
Your OSUMGP is now fully assembled!  Connect it to your PC/Console and verify functionality.