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Are you lifting the 4 Wiper lines from the POTs? or cutting traces on the board?I'm curious about the hardware you're using also. I see 4 Trim POTs on the breadboard, just wondering what they are doing? I used a 16F690 and a DAC104S for my design so the output of the Sticks went to the PIC, then PIC to DAC then the DAC to the controller board and the DAC uses the Stick voltage for the Reference, so it could be used on almost any controller that uses the same POT setup.
Yes those Sony controllers can be fun to desolder the sticks. Interesting project, looking forward to seeing how the PCB design goes.
You should be able to use a lot smaller Vias and components than 1206, unless you are making the actual PCB yourself? OSHPark is a really great place to get prototype PCBs made and they are cheap, but they make great boards. Their specs for 2 layer boards now are Vias are 10mil holes and 5mil annular rings, then 6mil/6mil trace/space width, so you can get that board to half that size there easy with 0603 components that are still easy to work with.
A 16.5mm x 16.5mm PCB from OSHPark is $2.15 for 3 of them. A 25mm x 35mm board would be $7.05 for 3. That's total costs, since shipping is free.
Nice looking boards. You can do any of the 4 Stick layouts in your code now since your board is between the Sticks and controller. Default, SouthPaw, Legacy and Legacy-Southpaw.