Could I leave the screws where they are and route out of the top and top mount the joysticks maybe using the same inserts? Maybe bold from the bottom? I have artwork and plexi to go over the top....
Here's a method that you might like.
Attached pictures are the base of Paradise's
Import Flight Stick. The same method should work well for the JLW.
1. Start by chain drilling (small holes close together in a line) the center square hole that goes all the way through.
Use router to smooth the edges of the hole
Make sure it is a snug fit for the joystick base to provide support and minimize shifting.
2. Insert the joystick base into the hole and trace the mounting plate and holes onto the top of the panel.
3. Drill the mounting holes.
4. Set your router depth equal to the combined thicknesses of the cover piece (1/8" wall panel used here) and the joystick top plate.
Carefully route out the outlined area.
5. Cut the cover piece to fit inside the routed area. Small gaps can be covered later.
Drill the center hole for the joystick shaft.
CRITICAL SPACING: Drill and countersink the two mounting holes in the cover plate. If they are off, the scews will tilt and the surface will not be smooth/level.
Attach nuts to hold it together.
6. Use bondo or spackle to fill the screw heads and gaps around the cover plate.
Tape over the center hole before sanding to keep dust out of the joystick pivot socket.
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If you decide to keep the inserts instead of using nuts, perform the procedure in this modified order:
* Step 3 - Use a small bit to drill through the center to the top then use that as a pilot hole for a bit one size larger than the screw, drilling from the top back toward the insert.
* Turn the JLW upside down to trace the mounting plate per step 2 using the screw holes to mount it. Also use a ruler along the side of the base to mark the extended line of all 4 base sides with 2 marks each.
* Connect those pairs of marks to draw the the outline of the base then drill/route it per step 1.
* Step 4 - Route out the space for the JLW top plate.
* Step 5 - Make the cover.
* Step 6 - Bondo/spackle as needed.
Scott