Question how would i design a controller pcb??

Stitches

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I'm assuming you're asking about designing boards like these for buttons and such?
1635124999697.png
 

Stitches

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Well your first step would be to jump on youtube and learn the basics of kicad, a free PCB design software. Then it's a matter of working out a control layout that you like and sizing/positioning the pads and screwposts in relation to whatever case and buttons you're using. You can order physical boards made to your design specs from JLCPCB.

There's also the frankencasing option, where you cut up an existing contoller board and solder wires from the button contact traces to the controller IC. Seeing as you're making a NES portable, there's no shortage of cheap single IC controllers to experiment with.
 
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