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Appreciate your sharing some details of the manufacturing trade-offs. It's more the size of the thing that baffles me, although it did make it much easier to work on. Okay there's a large antenna in there, but that just raises the question of why the antenna is larger than the antenna in a wifi dongle? And why add a 2m cable for a wireless dongle? Anyone who needs the extension could use an extension lead.
I'd also be interested in any speculation for why the fuse failed. As you say I had left it plugged in when I wasn't using it (I don't anymore), and even though I now have 9 extra spare fuses on hand I'd prefer to avoid any need to repeat that type of soldering. Other than loose connections I've never had any other USB devices fail whether they're high draw like charging a battery or low draw like a USB stick, or a wired controller.
They badly overengineered it. Both these things significantly improved reliability, because all other things being even a larger antenna will have much better signal characteristics than a smaller one of the same general design, and being able to place a receiver on the front of a computer rather than the back had a pretty massive difference. Some of those decisions weren't even crazy for the time -- the 360 released in 2005, where a lot of people still owned big CRT and plasma TVs designed for play from 6+ ft and built into furniture, and even for desktop computers CRT hadn't completely gone the way of the dodo yet, and especially major vendors will still big fans of making PCs (even gaming PCs) cases big thick piles of steel
There's a lot of more subtle goofiness like this : it uses a custom wireless protocol that was a lot less funky than bluetooth of the time in order to reduce latency from retransmits, for example.
The fuse existing is mostly a problem downstream of how the USB standard evolved. Originally, there was a hard 500mA@5V limit per USB port in the standard, but this was held more in principle than the breach; even by 2000 you could find cheap USB chargers that would put out 2A@5V ish, gfl. Wireless dongles were only supposed to use around 400mA, but even slightly sketchy source (eg, powered usb hubs) could push enough voltage to get at the fuzzy edge, and even if the dongle could tolerate that wider range, the wires (and some sources) wouldn't be able to supply it permanently without damage. As time went on and those skuzzy chargers became more common, it was just accepted (and saved money) to use fuses a lot less or with a much higher tolerance than the official rating, under the presumption that devices which could be damaged by sourcing more power would have safeties against it.
Why it failed is unfortunately probably more boring. While there are some potential weird cases (Five Below-brand USB hubs, badly implemented cell phone chargers, putting it on top of a wireless pwoer charger), chances are pretty good it's just time and entropy. Fuses, especially older SMD fuses, are both temperature sensitive and relatively fragile devices, since they work by breaking. Over time, a 500 mA fuse will become a 470 mA and then 450 mA, until eventually the intended current passing through the device will bust it. That's worse on wireless devices, since the antenna is basically an inefficient hot plate, and worse still with big PCB antenna like that particular dongle made, and worse still on devices like this that were pretty close to the edge of their power envelope to start with. The new fuse, especially if you bought it recently, is almost certainly going to be much more reliable, even under the same conditions. If you want to be extra-safe, I'd unplug it when you've got long periods where it's not in use, but it's probably going to be good for another 10 years.
Right, I hadn't considered how old the xb360 is. My last console was a PS1, after that I tuned out of the console scene entirely and largely out of PC gaming too until I picked this up around 2017. And my wifi dongle benefits from over a decade of improvements to wifi tech in an era when almost everything including the kitchen sink gained wifi, so not a fair comparison. Makes sense.
That's reassuring about the new fuse. I did match the original spec (250mA) despite some commenters on the fix-it page I was following suggesting using a higher rating. Better safe albeit with another blown fuse than sorry with a fried receiver.
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