Anyone here know of a place that makes custom controllers? By custom I mean CUSTOM and not just some paint job.
You get the odd one for disabled people, a few for developers that need sensing and the rapid fire/macro mod type things (see something like the evil controllers), and whatever keyboard and mouse mappers are doing this week. Something more custom like make these contoured section bigger, smaller, 10 degrees more inward turn, scale by ?%, relocate triggers/buttons... would be doable but no gamer would ever pay the money for it -- current controllers are either custom enough or locked down enough that you get to cannibalise one of those before doing anything, add in a few hours to do the CAD and play with a (good) 3d printer and it is not really viable, especially for something as personal as a controller ( http://theoatmeal.com/comics/design_hell is so very true).
Wavebird to USB sounds cool. I considered those GameCube style classic controller to USB but none of them have L3 and R3Ew gamecube controllers... to each their own I guess.
That said I think I would sooner build a wavebird to USB (and then 360) adapter. If it is for a 360 then probably easier to do like many of the keyboard and mouse adapters did and have a wired controller going into it to handle the 360 authentication, however all the inputs were handled by the adapter. Middle/dashboard button and back could be handled easily enough, the only real issue would be the left bumper button.