I'll also take a crack.
1) I Own two Aimtracks and they work great. In addition to working out the actual guns you should consider how they will attach to your cab, and where your LED board will be mounted. So, is it easy to hack a gun and make the aimtrak work, yes it was. Will it be easy to configure the rumble effect to work? I guess that depends on the gun and how it get's it's signal. I vaguely remember that guns like those require 12v instead of the 5V that USB provides, if this is the case you would have to bring up a USB cable AND another wire for the 12V (+1 for ground probably). So that's something to research first.
2) First of all, if you get a CP top from somewhere like GameonGraphics you may not even NEED a piece of plexi. However, it can look nice and provide some added protection. With that said, people generally prefer traditional plexi rather than Lexan, even though Lexan is easy to work with, it can scratch a bit more easily (I used Lexan, but sorta wished I used Plexi at this point.) As far as how is it held in place. There are pretty much 2 ways. The one stated above which is that the buttons hold it in place. If you do this, you should either use smaller MDF (5/8") just for the top, that way your 1/8 plexi + 5/8 MDF = 3/4 for T-molding. This essentially makes a slot border for your plexi to fit into and then won't fall/shift in anyway. OR, some people still use 3/4" MDF, but they offset the T-molding so the same effect applies, but they round the edges of the bottom of the CP so you can't tell (
See Mountains project here). Lastly, people use
black carriage bolts through the plexi ... this is also more "arcade standard" from what I can tell.
3) Check out this thread
HERE4) 42 BUTTONS? WTH?. Dude that's kinda alot. You might want to post pictures of your intended CP to get feedback or risk ending up on
CRAPMAME. I cannot imagine that you would actually need that many buttons.
As far as your list goes that all seems like a good option. I have used a lot of items from Ultimarc, but am not familiar with the Optipac or Happ trackball. I have spinners & a trackball from Groovygame gear that work great, and the nice thing is there is no need for an optipac with something that is USB plug n play.
I agree with the above post about those 4 vendors, they are really almost all you will need. As for the translucent buttons, unfortunately other than Lizard lick the only guy I found (ponyboy) is no longer selling them.
One last thing, if you do use LED's with the translucent buttons, you should use
button diffusers or go blind. Also, you don't HAVE to use translucent buttons to get a cool light up effect. I have two panels, one with translucent and one with opaque HAPP buttons (red, blue, yellow, and green) and both look really cool. At times I even prefer the opaque kind over the others. If you want some really powerful LED's to really bright up those opaque buttons
check these out. They are 100ma instead of the standard 20ma, so they will be a bit brighter.
My only other suggestions would be to check out the wiki, read other peoples projects for ideas (just sort by the most viewed) and be sure to post plans for constructive feedback.