It looks like you weren't heating it evenly.
Do you have access to an oven?
Triton:That post you replied to is from November, one of my first posts.
Since then, my opinion has changed a little. I still think that there is nothing you can do with frankencasing that can't be done with a well done vac-form.
That being said, I think the best solution is to form most of the case and salvage parts like button housings from their original controller. It can be done cleaner if you start from scratch, but you can get very nice results from incorporating both styles. No one said you could only use one.
