It took me a long time to figure out exactly how to make the patterns that go around the joysticks.
This thread by MikeDuece was one of my original inspirations -
http://forum.arcadecontrols.com/index.php?topic=105795.0This entire process would be much easier with a CNC. Since I didn't have access to a CNC I wanted to find existing patterns I could use. I spent hours walking through hardware stores looking for ideas. The pattern had to be big enough to go around a joystick but also be the right size to allow me to use pre-cut EL Panels. Ultimately the plumbing aisle yielded the best results and I used several different PVC fittings as patterns.

I carefully cut a sliver off the end of the PVC fitting with my chopsaw. This was more difficult than I anticipated because I was trying to keep the sliver very thin. The sliver was then sanded with my orbital sander to make it as smooth and level as possible.
I picked up a set of template guides off Amazon.

The premise is that the bushing works somewhat like a flush-trim bit using the PVC pattern as a guide. The bushing allowed me to use a very small bit--in this case a 1/16" double flute straight bit. Using a small bit has a couple of advantages. First I wanted to use the smallest bit I could find to avoid the "rounding" you inevitably end up with in the corners when routing. If you look at the "C" Ring I cut you can see the rounding at the ends of the partial circle. In that case I wanted the rounding for effect. These patterns needed to be more crisp. Secondly the smaller bit allowed me use a smaller PVC pattern. I could not find a flush trim bit that would fit in the grooves of my patterns.
Here is a shot of the bushing installed in the router.

I drew crisscrossing lines where I wanted the joystick to be and used those to center the pattern. Double-sided tape holds the pattern in place very nicely. I don't recall who on this forum gave me that idea but thanks. That stuff is magic.


Very carefully route out the pattern. The key here is patience. I turned off the router every time I had to move it from one section of the pattern to another.

And here is a shot of the partially finished laminate before I messed it up.
