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What are the cost of goods on components/labor? It seems like it would be worthwhile to manufacture a small run, if you think you can make your contracting rate. There seems to be bit of a move towards proprietary hardware (Boxee, Smith & Tinker, FitBit) in the star tup world so bringing a physical/electronic product to market is a neat/valuable experience.

Worst case you could just make it a "kit" and sell through AdaFruit or Sparkfun, in that case your cost will just be parts, a cardboard box and some miscellaneous packing materials.

Probably 20-30 in parts + 30 dollars for the controller + labor. Yes I would have to sell the xbox control with some minor labor done on it.

how would you do it? Sell premodified xbox controllers?

One way to get started might be to sell a kit? Even throw in the xbox controller.

I'll buy one.