Little bit of an update...
I have the new shell this sucker is going in and just need to address some final issues and this one will be a done deal.
One issue is the height of the sticks, even though these newer version POTs that Sony uses are the exact same height as the 360 ones, for some reason it's a tad on the short side when it's all together. That leads to the problem of just barely being able to press in on the Stick button if ya have the stick at it's outer most edge because the bottom of the sticks top part wants to hit the shell. To raise the stick height some I could have lifted the POT slightly off the board, but I opted to increase the shaft length for several reasons, 1 There was no way in nutz I was pulling them off the board after getting this far in the process, just too much work there, 2 It forced me to come up with something else, which is part of the fun in it for me, 3 Because it also increases the sensitivity of the stick slightly since it's a little taller, 4 It eliminated that 'play' that ya might notice if ya just barely move the sticks and 5 Because who wouldn't want that?
The spacer is just the tip of another 360 analog stick while the metal pin there is actually a shaft from a 360 Rumble motor. The PS3 stick had to be drilled a little bit to make it fit properly, as did the Thumb Stick caps of the 360, but it's a pretty solid setup now. (NOTE: If the spacer is too thick you'll just end up hitting the 'skirt' on the stick cap on the inside of the shell and it's going to rub or not move at all)
(IMG:
http://i50.photobucket.com/albums/f320/RDCXBG/PS360/PS360031.jpg)
(IMG:
http://i50.photobucket.com/albums/f320/RDCXBG/PS360/PS360032.jpg)
All that's really left to do is put the Stick caps on a Lathe and turn them down some to get the full 'throw' (range the stick moves from center to outside edge) back. If that's not done when ya have the stick moved to it's outside edge ya may notice in some games it's moving slower than it used to or like ya don't have the stick pushed all the way in that direction when mechanically ya really do. When these sticks are in the PS3 shell they have a little more room to move around, in here they're slightly cramped up and don't quite have the full range of motion. The PS3 stick caps I had in there before I sort of wanted to keep, but I had to end up using them on the 3PS360 stick because the 360 ones and that shell just don't get along, with this shell I could go either way, but in keeping it as opposite as possible from the 3PS60 I've just decided to go with the 360 caps.
(IMG:
http://i50.photobucket.com/albums/f320/RDCXBG/PS360/PS360033.jpg)
Another thing that could be done in this case is to sand or Dremel out the inside edge of the shell where the Stick hits, that will also increase the throw the stick has and is a lot easier to do, ya end up with the same result either way.