Almost 4 years past the original post... I hope this is "significant" or "essential" enough to not get deleted. I think this project was an amazing idea, but don't believe many people actually made these for themselves. Still, I refined the original idea, mostly by 3d-printing the entire shell. This should make these much easer to replicate for anyone with a soldering station, microscope and a dremel.
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I used a single sacrificial wired Gamecube controller for screws, PCBs, shoulder brackets and buttons. Also a Joycon grip for the metal rails and more screws.
The +, -, Home and Capture-Buttons are also 3d-printed.
I added extensions for proper JC rail releases instead of friction fits.
The orginal PCB is cut up and fits perfectly. There is no need for an extended stick mount since you just need to slightly trim the plastic peg. Other than that, the stickboxes are the exact same size.
The wiring and solderpoints is just as tricky as Shank describes, but the stick-clicks are not being pulled high. Also, my right joycon PCB was of the newer type with different antenna placement. Documentation on all the solder points is still lacking sadly. I became very good friends with my multimeter...
The 3d-printed shells have mounting points for the Z-Buttons, rumble motors, PCBs etc. Assembling everything is pretty straight forward.
Again, I just wanted to share the finished project and release the CAD Files for anyone who's only concern was breaking a perfectly good Wavebird. I didn't document much of the process since this is my first modding project.
Thanks to Shank for the great idea