dbrand Killswitch Compatible JoyCon 2 Controller Grip

I wanted a JoyCon grip solution that was compatible with the dbrand Killswitch JoyCon Grip Cases. The Stock grip that comes with the Switch 2 only allows the JoyCons without cases to be inserted. 

My design utilizes some parts of the original controller grip. The disassembly and entire build process is documented right here.

BOM:

• Nintendo Switch 2 JoyCon Controller Grip

• A set of 3d printed grip parts

  • Choose grip angle to your liking

• 4x M3 threaded inserts

  • Ideally 4.5mm in diameter

• 4x M3x10mm bolts

  • The bottom two bolts can be longer since the have more space

  • If you use the 20° mid-section you might need shorter M3 bolts at the top

• Tools:

  • Tweezers

  • 00 Philips Screwdriver

  • 2.5mm hex bit screwdriver

  • Heatgun

Printing Instructions

• 0.15mm layer height recommended

• 20-25% Gyroid infill, you can go beefier on the middle section if you wanna be extra safe

• If your adhesion is decent no brim required

• Orient as shown here:

• If you're having adhesion issues and have the short edges warping up, try adding small brim tabs. A layout like this worked perfectly for me:

Assembly:

This will be the step-by-step instruction for disassembling the original grip and assembly into the new Killswitch Compatible Grip.

Remove the four rubber plugs covering the screws. A pointy spudger or some tweezers work fine. The plugs are not particularly stuck.

Removing the plugs reveals two small 00 Philips Screws on each side of the grip. Remove those.

The cover is already removed here but I highlighted the location of the clips with green arrows. I found starting at the top was the easiest. Take your time and use plastic tools to not scratch or damage the plastic. 

Once the cover is off, unscrew the six screws holding the two main parts together.

Next part is a bit more delicate. I highly recommend a heat-gun to soften up the glue under the stickers. I've set my temperature to 85°C and low airflow and warmed up the sticker for about 30 seconds. Using some long thing tapered tweezers to start peeling from the middle cutout for the locating tab. The sticker is pretty sturdy, but still be careful.

The stickers reveal the parts we'll reuse on the grip. Undo the four silver screws to loosen the tray. Store them securely. Take out the tray and the two magnets underneath. Note the orientation of the magnets along their length axis. Keep them separate and away from any magnet objects. Keep the trays separate as well and note which side they came from (+ or -).

 Grab the middle part of your choice and the four threaded inserts. Melt them each into their spot.

Once cooled down and set. Get the two side parts, middle part and four M3x10mm screws. Assemble the three parts together.

Grab the trays with the magnets and insert it into the respective sides. The tray won't sit flush if it's on the wrong side. The LED holes help with orienting on the long axis.

Grab the four silver screws from before and mount the tray in the printed grip. 

Reapply the sticker and you're done. Keep the other parts of the original grip together in a box or bag in case you need/want to rebuild it to original.