I have a Logitech G603 and I like the battery time and the sensor, but the shape is really bad compared to an MX510, MX518, G7, G5, G400, etc. Is there a way to replace the outer shell somehow to have a different shape or add a groove for the thumb and make it a little bit wider? I wonder if somebody did something similar or if there are any best practices regarding to this?
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I cant help but feel like just buying a different mouse would be the best route here, but on the other hand, I could see 3D printing a new shell for the mouse being possible, but the skills and tools required for this would be on the upper end of DIY i would think.
DWolvin
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Subbed for the wise knowledge that will arrive at some point... 
I did not find any mouse that would meet my criteria in the last 10 years. I doubt I will ever find unless they come back with the G7 updated with new sensors, which I doubt. Other manufacturers do the same, there is no wireless gaming mouse with grooves for the thumb and ring finger. Otherwise I would already have that mouse...
I am thinking on making a prototype from wood and ask somebody after that to print it for me. I have zero experience with plastic or 3d design, but I know a few people who have.
Nobu
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If you have half decent measurement tools you can make a sketch and write down the dimensions, then someone can draw it up in 3d design software. The big thing will be getting the inside so it somewhat matches how the original shell held the sensor and lazer, so that it is reflected off the surface correctly.
I was thinking on glueing the panels to the G603 instead of printing a complete new shell. It is a lot easier I think, and I don't care much about how it looks like. I never use the side buttons either, so covering them is not a problem.
At most $50 for the material. As of the tools I don't know. I like to spend on new tools.
Somebody told me that modding the G305 is the way to go and Piranha mouse modding is already doing it. They just don't have a mod for G5/G7 yet. I'll ask them, maybe they have a good advice. https://pmm.gg/ https://www.youtube.com/channel/UC4zaMlZWpTmfc-jRviifCiA/videos
I had some progress. I tried to find a G7 second hand, but even the cheapest ones cost the same as a recent wireless gaming mouse and I don't want to make this kind of nonsense business when all I need is scanning the shape or using the upper part of it. I might be able to get a G5 shell from a broken G5, currently discussing it with a guy. So hopefully that solves the issue. I have a G400 for a worst case scenario, but I don't want to paint that for scanning.
For scanning I found this video:
Not sure if photogrammetry will give back the shape properly, but I have no other option. Simple laser scanners start around $400 and advanced ones around $1500. It would be too expensive for a mouse and I would not use it for anything else. For printing I'll buy a Creality Ender 3d printer, it is around $150-200, and in theory it is a good one for a beginner. I plan to use food grade PLA filament and food grade epoxy resin to seal it.
I am not sure that my G603 is good enough for this project, because its inside is very complex and it is connected to its outside, so I'll have to replace both. :S The only workaround would be printing side panels with grooves and glueing them to the mouse. It would work I think, because there is no huge difference between the old Logitech shape and this one, only the grooves are missing. First I'll scan both mice and check if I can design good panels based on the difference. If so, then I'll mod the mouse this way.
For the bigger project I might need to buy a different mouse that is easier to mod. The easiest way to use the PCB of a wireless mouse and use the shell of an exisiting mouse and print the bottom part. The shell donor can be G400, G5 or MX518, does not really matter which one. I already found such a project with G703 and MX518. https://www.instructables.com/Logitech-MX518-Wireless-Mod/ Scanning and printing the upper part of the shell is the hardest way to do it, because it is not flat like the bottom part, but I think it is doable. Just not with my current skillset... If I can do it, then I'll add some design too, probably white PLA, transparent resin and some flames inside the resin and my custom logo, because inferno you know. But that won't happen today or tomorrow...
For scanning I found this video:
Not sure if photogrammetry will give back the shape properly, but I have no other option. Simple laser scanners start around $400 and advanced ones around $1500. It would be too expensive for a mouse and I would not use it for anything else. For printing I'll buy a Creality Ender 3d printer, it is around $150-200, and in theory it is a good one for a beginner. I plan to use food grade PLA filament and food grade epoxy resin to seal it.
I am not sure that my G603 is good enough for this project, because its inside is very complex and it is connected to its outside, so I'll have to replace both. :S The only workaround would be printing side panels with grooves and glueing them to the mouse. It would work I think, because there is no huge difference between the old Logitech shape and this one, only the grooves are missing. First I'll scan both mice and check if I can design good panels based on the difference. If so, then I'll mod the mouse this way.
For the bigger project I might need to buy a different mouse that is easier to mod. The easiest way to use the PCB of a wireless mouse and use the shell of an exisiting mouse and print the bottom part. The shell donor can be G400, G5 or MX518, does not really matter which one. I already found such a project with G703 and MX518. https://www.instructables.com/Logitech-MX518-Wireless-Mod/ Scanning and printing the upper part of the shell is the hardest way to do it, because it is not flat like the bottom part, but I think it is doable. Just not with my current skillset... If I can do it, then I'll add some design too, probably white PLA, transparent resin and some flames inside the resin and my custom logo, because inferno you know.
But that won't happen today or tomorrow...