If your etching a PCB and putting it in a box why not cut the xbox plug off and connect the wires with .2" screwdown connectors or solder them directly to some fat tracks and then deal with the 4 remaining wires (GND, +12V, +5V, PWR ON) through a nice sturdy plug / socket combo going to your reprap.
Also your gonna have trouble even with a double sided pcb as you can only solder the bottom layer to your connector and the top tracks would barely be connected, if at all due to a lack of plated through holes in the pcb and the fact that your connector is sat directly where you would need to gain access to make the top side solder joints.
Edited 1 time(s). Last edit at 06/17/2013 04:38PM by slymike.