I saw the little PC board that someone is selling on the Web, but I wanted to brushup on PC layout techniques and low-volume PC board manufacturing (aka diy PC boards). I measured the size of the connector on NunChuk and used the pin-out information I found and designed my own board. It is a two-sided board without plated-through holes (which causes yet other problems). Since the individual boards are so small, I decided to do a strip containing 4 at a time and then cut them out for use later.
These work great. Here are some pictures. I beg your forgiveness on the sloppyness of the soldering as I had hole drilling problems and non plated holes.
I printed the image using a laser printer on photo-paper, a hot iron to transfer the image to the board, water to remove the paper, and etched using a 2-to-1 mixture of Hydrogen Peroxide and Muriatic Acid. The etching itself only took about 2-3 minutes – very fast. I didn’t have the correct drill bits (this time around), so I kindof burned the holes with a wire (not the recommended way to do this). Since I made these I have invested in the appropriate drill hardware.