Hey Ben!
I think this would be right up your ally since you love modding controllers.
One of my favorite games in DanceDanceRevolution and there have been many fans creating their own version of an arcade accurate platform for home use.
A popular thread for many years on DDRFreak shows hundreds of fans trying their best to create a good home version platform with many different designs: http://www.ddrfreak.com/phpBB2/viewforum.php?f=37
There are two main ways pads have been made:
1) Using sensors, 4 under each arrow just like the arcade: http://media.rhythmatic.net/gallery/v/machinesdb/piu/parts/004cyp78.jpg.html
2) Using sheetmetal under each arrow: http://media.rhythmatic.net/gallery/v/machinesdb/impact/
The first method is preferred because it allows much better sensitivity in the corners of each arrow. Many DDR players play very tightly towards the center of the platform using their toes and heals to hit the arrows.
This is one home version build that has a lot of histroy behind it called the BeatGear that only a few survived after some unknown trouble. I only know of 4 that still exist and none with bars. http://media.rhythmatic.net/gallery/v/machinesdb/beatgear/
I've been playing this game for more years than I probably should, so I would to assist you more with this build if you choose to do so!
I would love to see more arcade type builds. I watched much of your Bill Paxton pinball build on YouTube and loved it!
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