Drilling holes for MK2 Control Panel

[KITTinKC]

Hey, everyone.  I'm finally at the stage to start on my custom MK2 control panel.  I have Happ classic buttons and Happ competition joysticks.

Just some n00b questions  :

- Do the buttons use 1_1/8" holes?

- What size do I need for the joysticks?

*I know, you're probably saying, "just use the same thing they did with the original CP".  But, since I'm not 100% sure if the buttons/joysticks I have are the exact same thing they used back in '93, I just want to make sure.  Again, they are Happ classic buttons and Happ competition joysticks.

- What bit would be best for a clean hole?  Preferably for a drill or drillpress.  I don't have a router.

- Is the larger, black washer needed with the joystick (on top of CPO, under directional stick)?  I've seen some with and some without - I'm trying to keep it as close to an original MK2 CP as possible.
EDIT - Or does it go on top of the CP, but under the CPO?  (Thus, I would need the "countersink")

- The old control panel had larger "countersunk" holes around the drilled-thru holes (probably not the right terms to use but best I can think of right now).  The buttons had a 1_3/4" countersink around them on the underside of the CP, and the joysticks had a 3" countersink around them on the top side of the CP.  Is this necessary?  My CP will be 3/4" thick.



- If I need to do that, what is the best bit or method for doing so?  Forstner bit?

Thanks in advance for any help!

[Donkey_Kong]

I'm really not the best guy around here to answer this, but I will give it a shot anyway. It seems like most of your questions can be answered from the happ website. http://na.suzohapp.com/

The underside countersink holes aren't necessary as i think the shaft of the pushbuttons are plenty long.

The spade bit works but a forstner bit is way better I think. 1-1/8 for pushbuttons. Drill press preffered but just go in straight as you can with a handheld drill practice in some scrap first...but not too small a piece drilling into a small piece of wood can be dangerous.

You have to check the diagram for your joystick sizing, the dust washer should go on top of the control panel.

[KITTinKC]

Thanks for the help!

[eds1275]

With a 1 1/8 drill bit if you don't go 100% straight it may be hard to get the button in or to go flush with the top. A generally use a router to clean up the holes by running a flush trim bit around the inside of the hole going from both the top and bottom. But a small hand file does just as good though takes a little longer. Buttons should drop in pretty easily but not have any wiggle room.

[yaksplat]

Best case scenario is a forstener bit in a drill press.  You'll have perfectly round and straight holes with smooth sides.