After researching some more on the forums, I definitely decided the original control panel size was not adequate for room and the button layouts with a trackball. I only used measurements given on some post's in the "Show off your control panel" thread, as most did not give their dimensions. *This would have been nice to know, since its hard to gauge the size of a panel from a picture*
This also meant I would need to build a new slide out panel. So I got to work using 3/4, pictures for an idea and drawing on the wood sheet. This is what I came up with and I love the extra space. Feels more comfortable. I only designed this in my head (took about four hours) just staring at the cabinet, then drew it onto the wood and cut it out.



I took a construction idea from the original panel of using small footers along the walls of the control panel. This provied an extra area to screw in the sides for more support, which prevent any flexing and the possibility of the screws ripping the 3/4 sheet as the base. I am impressed at the extra strength it provided. All external screws utilized a pilot hole, countersunk, filled in and sanded. I did not spend the extra time of filling/sanding the internal screws. Mainly because I wanted to know where they were just in case.
Now it was time to cut out my control panel top. I combined a few different ideas from completed projects.


Finding and printing out "to scale" layouts was a pain in the butt. After that was done, I mocked up the control panel. I came to a decision and pulled the trigger as the new control panel art will lay over this, no intricate designs are in the art.




I added the chain like the original had to prevent over extension of the panel and also it keeps it upright at a slight angle if I needed to work on it. I also added a door magnet set to keep the panel locked down.

This is where I am so far. The old coin slot cutout in the front will house a computer speaker subwoofer enclosure and a 200mm case fan for added air flow, but that is another day. I'm currently hunting for a decently priced 27" tv to use as my monitor, picking up a Logitech S220 computer speaker system. I am completing my program portion of the build on my desktop, so far I have Hyperspin running Mame 1.43u6, Mess for Atari 5200 and Nestopia for NES. Working out the bugs on the NES roms. I would like to add SNES and maybe NeoGeo and thats it.
So far, I think its turning out good. Thoughts?