Got some work done on the cabinet finally today. My wife was gone all afternoon, daughter was napping, so the boys and I got to work.
Cut out the shape of the control panel top, which i had marked a few nights ago so it was ready when i had a chance to cut. i then drilled small pilot holes through all of the button locations, flipped it over and started drilling from the back, just a little to help prevent blowouts. then i flipped it back over and proceeded to drill them out with a 1 1/8" forstner bit.
I wanted to keep the button holes as straight as possible, so i used a drill guide i picked up at harbor freight, which keeps the drill at a 90 degree angle, i highly recommend these if you don't have a drill press.
all buttons holes drilled, as well as the 3" hole for the trackball.
flipped it over, routed out about half the thickness of the panel for under mounting the JLW joysticks.
i then placed the plexiglass on and used the 3" hole in the mdf as a guide to cut the trackball hole in the plexi with a flush trim router bit. i made sure there was an overlap of plexi on all sides of the panel.
i then removed the plexi, marked the location of the trackball plate and cutout area for the trackball. I also used a 3/4" spade bit to counter sink an area for the T-nuts that I will use to attach the joysticks.
i cut out the hole for the trackball with a jigsaw, then used the router to recess an area for the mounting plate so it will sit flush with the surface of the panel.
i mounted the trackball mounting plate to make sure it fits, and also installed all of the t-nuts for the joysticks. I used a large bolt as a punch and pounded them in with a hammer. (making sure to have a block of wood under the back to make sure it was supported during the pounding)
Here is a shot of the t-nuts which are recessed into the top of the panel
my 4 year old helping me attach the nuts for the trackball plate
i didn't bother making a guide for perfect routing...just free handed it....isn't that great of a job, but it works, and you wont see it.
then came time to start cutting button holes in the plexi. i placed it back on the panel, lined up the trackball hole with the mounting plate, clamped it and then started. i placed the 3" hole saw in the hole to help keep it lined up while i clamped it.
i have tried many methods over the years for drilling in plexi, but this is by far the best way i have found. i used a V groove router bit in my trim router, and slowly lower it into the button hole for a pilot hole, then use a flush trim bit to make them nice.
i only got about 3 holes done until i had to quit...my wife came home and supper was ready. i had to then pack up for the day. I am hoping that tomorrow afternoon i'll get to finish doing the button holes, trim the plexi around the outside edge of the panel, and cut the slot for the t-molding....i guess time will tell. I also did a test fit with the trackball installed, the edges of the plexi are a little sharp. I see some of you have used a 45degree chamfer bit to make this edge nice, but i do not have one of those. I checked harbor freight, but they didn't seem to have any cheap ones. The cheapest i have been able to locate one locally was about $18, which is more than i'd like to spend on this. i do have a roundover bit, do you think that would work? i guess i could test it on a scrap tomorrow....i just told my wife i wouldn't spend any more money on this thing for a while.
i brought it in and placed it on the pedestal to see how it looked...
I then proceeded to place the buttons in the holes, mainly just because i could. i am on blue button short, but i can steal one from my other cabinet, i just used my coin button temporarily to fill the hole.
i'm pretty happy with the overall feel of the panel and the button layout. i can't wait to get this thing working.
That is it for today. i've just about finalized my overlay artwork, hopefully i'll be able to get that printed soon. Once again I am at the mercy of my wife on that one. I also need to pick up some black paint....i wanted to paint it dark green, i already have red t-molding for it, but she shot that idea down pretty quickly. it would clash horribly with the walls in the room...i guess you win some, you lose some.