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21Test 2
Move the slide switch back to chrg. Plug a microUSB cable into a cellphone charger and into the charging port on the outside of the top half of the case. The charger should light up. It will be red until the battery is fully charged, then turn green. Don't wait for it to turn green. Check that it works and then disconnect the charging cable.
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22Epoxy wires in place
Using the photos as a guide, epoxy the wires in place.
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23Assembly of the case
Place pushbuttons into the two holes. The longer pushbutton belongs on the outer position (close to the edge of the case). Lift the controller off the table so the buttons are suspended by gravity. Rotate the buttons so the tabs are lined up with the slots in the case and the buttons fall into place.
Close the two halves of the case. This is tricky. Push the battery connector and its wire towards the empty space in the top part of the case. The cable for the pushbuttons should be kept so they do not interfere with the pushbutton action. Use a thin screwdriver to manipulate wires as you close the case. Avoid trapping the wires either on the outside edges of the case or by one of the inside posts.
Make sure the case closes completely and evenly. Thread the 7 screws (4-40 x 3/8") one by one into the bottom of the case. Make the screws firm, but do not over-tighten.
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24Test 3
Sometimes the pushbuttons press down on one or both tactile switches once the case is closed. Pressing the pushbutton should produce a nice click sound, and when the controller is ON, the red keyfob light should be off unless the pushbutton is pressed. If the pushbutton is pressing too much on the tactile switch, open the case, remove the pushbutton and scrape off any residual plastic in the base of the pushbutton. The pushbutton should have a slight, but discernible recess in the middle of the base. If cleaning out the pushbutton base does not work, you may have to sand down the pushbutton with sand paper or emery cloth (100 to 200 grit).
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25Test 4
Fully charge the controller. The slide switch must be set to "chrg". A light on the charger board will be red until the battery is fully charged, then it will be green. Charging can take hours. Take the controller to a receiver (presumably the Play Video player). Turn the controller ON and test each pushbutton. The controller should work just like a 2-button keyfob. On a full battery the range should be 5 or 6 feet. Each time you press a button the controller, the red LED on the internal keyfob should light. If the keyfob lights, but one or both switches does not work (or the signal seems weak), you may have a problem with epoxy on the keyfob board. Review Step 7, especially the red zone in the picture.
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