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it's part two of the solid gold xbox controller odyssey and by the end of

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this video we are planning to be done but we definitely have some problems to

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solve not with this piece mind you but with some of the other ones the shoulder

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buttons for example used to have plastic linking them so now there's no give are

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they going to press properly we don't think so so we need to figure

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that out the battery cover well

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it used to have plastic clips that fit in a thing and

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now it doesn't go in either so we're going to have to solve that problem too

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furthermore the entire fit and finish of this thing i mean

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obviously we can't just screw it together the way we used to

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how do we join it we're thinking laser welding but

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i mean is it going to fit together okay

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well we got a wardrobe change here where'd i get this cool foil controller

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shirt obviously lttstore.com the first

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processing step is using a tungsten carbide burr to quickly turn the sprues

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into expensive glitter well

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very very expensive glitter now under normal circumstances expert castings

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wouldn't offer any kind of compensation for this material being removed onto the

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floor which made me very uncomfortable about how

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much money i was going to be losing throughout the grinding and finishing

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work thankfully we worked out something where we were going to weigh the

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finished piece and then go based on that for pricing

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before we can do any of that though we discovered some

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small holes in the gold controller which need to be filled and honestly i'm kind

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of glad they're there because getting to see this process was super cool freaking

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lasers baby this is the roofin star weld

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dx and at first i assumed that it was just kind of like a fancy way to solder

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or something like that but no this thing is capable of shooting up to an 8

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kilowatt laser pulse that will instantly melt the metal that it strikes so

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basically you'll line up this filler wire and your part with the cross hair

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in the microscope put the pedal to the metal and bam you're welding

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mechanically it's quite similar to arc welding even using an argon assist gas

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but instead of using electricity to melt the metal

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you're using coherent light with the holes filled it was time to

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decide on a texture for our finished surface now one of the best things about

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the new generation xbox controllers is just how grippy they are and although

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the casting was able to retain a shocking amount of that fine detail

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well we've got a couple of problems first of all the surface is going to

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have to end up smooth wherever the sprues were attached and it's unlikely

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that our factory texture would have survived the polishing that was required

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to get a shiny finish anyway so we decided to go with a custom

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texture the goldsmith hendry here showed us two test textures on the inside of

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the battery cover and let us pick one of them he described as snake lightning and

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the other is more like a hammered or golf ball finish

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now we assumed that these were finishes that he like applies regularly but it turns

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out that this process is actually more art than science apparently he just kind

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of looks at the surface of whatever came out of the casting and does what feels

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right anyway the snakes spoke to me so

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that's the texture that we're going to end up using for the entire piece to

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look cohesive though a little bit of planning is required in this case laying

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out the rough lines to follow using a sharpie and like i know they do this

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every day and i trust their workmanship but i still really struggled watching

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the first few marker lines and bits of grinding because to my untrained eye it

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kind of felt like halfway through a bob ross tutorial where the canvas still

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looks like a blob of happy green and brown accidents

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full credit though once it's done

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it looks so good oh my god that looks

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so awesome oh man we had some concerns

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about the shoulder buttons because we thought this piece in the middle would

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have to flex because it normally would be made of plastic but they actually

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work like fine they're awesome nah it'll be fine

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don't you stress alex as cool as snake lightning looks though it's more of an

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accent finish than what we want everywhere for the top we want that

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classic smooth blingtastic mirror finish and achieving this is no

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mean feat given how many imperfections are left behind by the casting process

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so in order to get there we start with what's called a porosity hammer see that

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it spins so what it's doing then is many

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times a second it's hitting or hammering the higher parts of the

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material and then spreading them into the lower parts creating a an almost

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perfectly flat surface now because our part was so big henry actually had to

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put aside some of the porosity hammers that he's already created for himself

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and make a custom one out of this screw he told us this wasn't cool and i was

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like you make your own rotary tools what do you mean that's not cool

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of course that's not enough to get the mirror shine so we also need some love

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from the polishing wheel brothers over here

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so it was porosity hammer polishing wheels porosity hammer polishing wheels

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uh rinse and repeat for oh about a day and a half due to the size of the part

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one thing you might have picked up on at this point is that you know

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the outside of this xbox controller and all the parts are made out of plastic

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which is not electrically conductive whereas the gold one

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is pretty much as electrically conductive as possible so

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i need to make sure that we won't have any shorts or anything so i'm going to

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come in here with the good ol acrylic conformal coating and just

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give her a blast

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now we just do that like four or five more times another problem that i

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noticed is that the battery connectors

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come up like this and if it's touching the gold again you're going to have

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short problems and i think even in formal coding it

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won't do us enough good now one big plus

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is that i ordered a rechargeable battery

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and that one you don't have to do this end which is much harder to deal with we

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only need the two contact points so i think

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as long as we do the conformal coating and then we just add in some electrical

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tape on the side inside here we should be fine final assembly time

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now that i've got the trigger buttons on the plan was actually just to test fit

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these pieces and this one but this piece

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is so finicky to get on and off that i'm

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sorry guys we're just we're not going to see that process on video because we

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don't want to do any more damage to these little plastic nubbins here the

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thing is when you're putting plastic on plastic there's a lot of give you can

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kind of slide things over each other and they don't destroy each other with metal

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there's no such give so there's a strong risk of just breaking things off

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so we're just gonna we're gonna leave it the way that it is um another concern that we had was

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fatigue failure so gold is particularly prone to this you do the same thing with

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it over and over and over again and like these micro cracks form until finally

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just it comes apart but looking at how little flex honestly

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alex i don't think it's gonna be a problem yeah i think it's fine and the buttons

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feel surprisingly good like we had concerns about these

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springs being strong enough because it weighs so much more kind of like on a

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gaming keyboard right if you put a metal key on top of a cherry mx switch it

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dramatically changes the actuation force here

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feels great listen to that clack though

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now comes the most fragile piece basically they told me

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as soon as you touch this it no longer has a perfect finish anymore i'm like oh

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okay no pressure or anything just put my gloves on really there's nothing that

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makes me feel more inadequate than a one-size-fits-all glove oh come on baby

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you can go one there okay all right all right all right all right all right

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let's get it let's get it assembled okay now these screws were originally meant

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to go into plastic last thing we want to do is like over torque it here all

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buttons work on the on the top of it now let's try the face

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everything's good this is very promising

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okay this one is going to be tricky because you got

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these little tab and nubbin things here and again remember plastic on plastic

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flexible metal on plastic not flexible metal on

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metal super not flexible kind of need it to

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oop so you got these pieces that go in over here never given this much thought

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to it wow does it get it just went right on

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were you expecting that

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oh oh okay

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last piece bottom cover

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this one's a little trickier because remember this is the part that got a

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little mangled when there wasn't enough gold in the

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mold uh

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that's it okay alex do you have gloves

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okay get get some gloves it's

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so heavy

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oh wow

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i knew it would be heavy but it's so heavy i know right

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even holding the individual pieces of it is looking all this thing's pretty heavy

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her and the clad the clack so good

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i know right as brutal and painful as this is guys we're gonna do the glam

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montage now okay before we mess it up but the actual

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experience of trying it we're going to get everyone in the office to try it out

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we're going to make a video with everyone experiencing it that is going

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to be a part 3 video because i just got

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to be honest with you guys like this was very expensive to make and i

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LTT so give it a try and start protecting yourself from bad times

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if you guys enjoyed this video and you love crazy projects you can go check out

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part one we're gonna have that link down below or you can check out our water

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cooled playstation project or i don't know water cooled camera we've got lots

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of crazy projects we've done over the years this

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this might just take the gold medal though

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got him