Donkey Kong scratch build, my first cabinet!

[PixelPaul]

I finally decided the time is now to start my first cabinet. Ever since I was a kid I dreamt that someday I would have my own arcade game room. Fast forward 30+ years, and that time is now. Shortly after moving into our new home I began looking at CraigsList and eBay for arcade games. I was a bit surprised to find they could be found, but in good condition they were quite pricey. It wasn't long after I started looking around that I discovered the world of MAME and then this forum. It was an easy choice to decide to build my own cabinet, as it would combine my interest in computers and my enjoyment of woodworking.

I can vividly remember my first encounter with video games. Walking into Skateworld one day to find a small crowd gathered around a single Space Invaders game. After squeezing my way through the crowd and getting my first glimpse I was mesmerized. It was the coolest thing I had ever seen and I was hooked before even depositing my first quarter. Over a period of time that one arcade machine at Skateworld would grow to around a dozen. I remember all the classics being there - Pac-Man, Donkey Kong, Missile Command, Centipede, Space Invaders, Asteroids, Frogger, Pole Position and Zaxxon, with a couple of other titles periodically rotated in and out.

For a young teenager growing up in rural Wisconsin, the local Skateworld was the only arcade option. I remember my mom dropping us off for an afternoon of roller skating (or so she thought) with enough money for admission, skate rental and some food from the snack bar. Instead of skating we would sneak in the side door ($1.75 admission saved), not even bother the rent skates ($1.00 skate rental saved) and go without snacks ($1.50 saved) and spend everything at the arcade. Some really great memories of my youth took place there.

I'm sure everyone has their own favorite game, the one you would always gravitate towards when you were down to your last quarter. For me it was always Donkey Kong. I'm not sure exactly why, as I don't recall ever really being very good at it, but it always was and still is my favorite. So for my first cabinet I'll be building a Donkey Kong cabinet from scratch. For all you purists out there, beware! I plan on making a few modifications, so it will not be 100% authentic, but I think the finished product will do my favorite game justice. I'll do my best to document the build in this thread in hopes other might find it useful. Stay tuned!

[yotsuya]

So for my first cabinet I'll be building a Donkey Kong cabinet from scratch. For all you purists out there, beware! I plan on making a few modifications, so it will not be 100% authentic, but I think the finished product will do my favorite game justice.

If you're building it from scratch, no one will mind. 

[skjerk]

Subscribed! 

[gabrielmtl]

Same here, subscribed.

[wp34]

This is on my list as well so I'll be interested to follow your progress.  Welcome to the forum!

[PixelPaul]

For this build I'll be using the Jakobud plans. In reading these forums I've come across comments that these plan dimensions are not 100% authentic, but I think they will be plenty close enough for me. I'll be using 3/4" MDF for the cabinet construction. Considered 5/8" to keep the weight down a bit, but none of the local big box home improvement centers carry that size, so 3/4" it is.

Made a run to Home Depot today to get some supplies for the cabinet construction. Forgot to swap cars with my wife before she left for work so I was not able to get the MDF panels (not going to fit in a Corolla!). Picked up some other materials which included:
titebond yellow glue
Drywall screws, 1-1/4" to attach poplar cleats to MDF
Spax screws, to attach MDF panels
wheel casters
poplar strips, 3/4" x 1.5" in random lengths to use as cleats
poplar boards 3/4" x 2.5" for base


I did some research into MDF fasteners. In the past I've used drywall screws with pretty good results, but found something called SPAX at Home Depot. Supposedly designed specifically for MDF. It says no pre-drilling required, but I can't imagine how effective that will be having worked with MDF before. Will probably pre-drill anyway, but thought I would give the Spax screws a try.


Also picked up 4 wheeled casters. I know the original Donkey Kong cabinet did not have this, but being able to easily move the cabinet was a feature I wanted to add. There will be two swivel casters at the front and two locked casters in the back, so hopefully it will be easy to move around. The wheels will be inside the black base surround and protrude about 1", but when placed on carpet I think they will be hidden and the cabinet will look like it is resting on the base.

Spent ~$45, Total Cost to date: $45

[PixelPaul]

I had a bit of time before work, so why not get started building the base. The Jakobud plans call for 2-5/8" material, but Home Depot only had 2-1/2" poplar boards. Poplar is a good choice here - strong, cheap and paints well. The slight change in dimension was an easy choice compared to buying something wider and ripping to the "correct" width without a table saw. I considered making some nice 45-degree miter cuts for the base, but didn't feel I could get accurate enough angles with a chop saw or circular saw. Decided to go with a basic butt joint.


Simply cut boards to length with the chop saw, drill some pilot holes and fasten with some drywall screws and yellow glue. I countersunk the screw heads and will later cover with bondo and sand flush before priming and painting.


The wheels will extend around 1" above the base, but the carpet will hide some of the wheel and give the appearance that it is resting on the base (I hope).

Work Time ~ 1:30, Total time to date: 1:30

[EMDB]

...

Work Time ~ 1:30, Total time to date: 1:30

Don't count your hours spent! 

[jdbailey1206]

Good to see another DK cab.  I followed the Jakobud plans for my build and they really arent that far off.  I've gotten to my favorite part of the building process.   Painting.  Ugh.  Don't worry about counting  your hours.  It's like watching the clock on a road trip.  Just isn't necessary.  Sit back and enjoy the ride.  And update with plenty of pics.  Even when you make mistakes.  It will give the next guy a heads up on what not to do.  I'm looking forward to the next update and welcome to the forums. 

PS Start looking for a coin door now.  They are rare.

[PixelPaul]

Don't count your hours spent! 

Doing it out of curiosity, really. I don't really care how long it takes. I enjoy building things and woodworking is a hobby. If I wasn't building this I would likely be making something else. In fact I imagine I will enjoy building the cabinet just as much as I will playing it.

[PixelPaul]

PS Start looking for a coin door now.  They are rare.

So I've noticed! Been keeping an eye out for one for a while but haven't found anything yet. Been going back and forth in my mind what to do about the coin door. Refurbish an original (assuming I'm able to find one) install a new one (which won't look 100% original but I don't think most would know the difference) or forgo the coin door completely in favor of some artwork. The graphic designer in me says go with some artwork where the coin door should be. Not sure what direction I'll end up going.

[PixelPaul]

What's a benefit of working at a commercial printer? Access to large format printers. Made for easy work for creating a side panel template. Scaled jakobud plan to actual size and less than 5 minutes later, viola!



Otherwise a minor setback, my wife's Ford Explorer is in the shop and won't be able to pick up MDF panels today. Was hoping to have them for this weekend :-(

[mcseforsale]

Looking forward to this.

subscribed.

AJ

[mgb]

Welcome pixelpaul,
  I'm looking forward to following this project.
I look forward to seeing the mods you make too.
It's so true about having that game that just holds a strong
nostalgia for you.
For me it's always been crazy kong more so then DK
which is odd but its because that's what was at the corner store
by my house when I was young. I actually played that before I
ever saw a DK. Also Berzerk always held a special place too.

Good luck on the build. I think counting the hours may cause you
to either go crazy or drink heavily but good luck

[Slippyblade]

What's a benefit of working at a commercial printer? Access to large format printers. Made for easy work for creating a side panel template. Scaled jakobud plan to actual size and less than 5 minutes later, viola!

Just so you know, I now officially dislike you.   

I kid, really. I'm just jealous.

[SORHP]

Awesome endeavor!!!

Can I offer some advise having built a Nintendo cab and restored one..,

Buy (acquire) all your hardware first before cutting wood, it will help tremendously when needing to fit metal parts on the wood pieces incase jakobuds measurements are off (which I hear they are in a few places)

Have a blast!!!, can't wait to see the progress!

[SORHP]

Awesome endeavor!!!

Can I offer some advise having built a Nintendo cab and restored one..,

Buy (acquire) all your hardware first before cutting wood, it will help tremendously when needing to fit metal parts on the wood pieces incase jakobuds measurements are off (which I hear they are in a few places)

Have a blast!!!, can't wait to see the progress!

[SORHP]

Awesome endeavor!!!

Can I offer some advise having built a Nintendo cab and restored one..,

Buy (acquire) all your hardware first before cutting wood, it will help tremendously when needing to fit metal parts on the wood pieces incase jakobuds measurements are off (which I hear they are in a few places)

Have a blast!!!, can't wait to see the progress!

[SORHP]

Awesome endeavor!!!

Can I offer some advise having built a Nintendo cab and restored one..,

Buy (acquire) all your hardware first before cutting wood, it will help tremendously when needing to fit metal parts on the wood pieces incase jakobuds measurements are off...

which I hear they are in a few places


Have a blast!!!, can't wait to see the progress!

[SORHP]

Awesome endeavor!!!

Can I offer some advise having built a Nintendo cab and restored one..,

Buy all your hardware first before cutting wood, it will help tremendously when needing to fit metal parts on the wood pieces incase jakobuds measurements are off...

which I hear they are in a few places


Have a blast!!!, can't wait to see the progress!

[PixelPaul]

Can I offer some advise having built a Nintendo cab and restored one..,

Buy all your hardware first before cutting wood, it will help tremendously when needing to fit metal parts on the wood pieces incase jakobuds measurements are off... which I hear they are in a few

This is sound advice indeed. However I will likely be printing all my artwork at my job (have access to equipment), so I will have the ability to make things whatever size is needed.

[PixelPaul]

My wife's SUV is finally out of the shop so I was able to go and pick up the MDF panels. A few words about MDF. A 3/4" x 4' x 8' panel is VERY HEAVY and it is not the easiest thing to move around such a large size. This is definitely a two person job. Fortunately our local Home Depot has a panel saw, and is able to cut the 4' x 8' sheets into a more easily manageable size. Just make sure to plan out your parts cut list to maximize the pieces you can get out of each panel. I figured two 4' x 8' sheets would get me all the parts I needed, minus the back (probably use 1/4" plywood for this). Despite the heavy weight of MDF, it can be fragile. Corners can easily be crushed or broken off. Load and unload with care.



Spent $70 for MDF, Total spent to date: $115

[PixelPaul]

Now that I have the sheets of MDF, I started work on the cabinet today. First a public safety announcement. Cutting and sanding MDF will create a plume of fine dust that will cover everything within about a 15' radius once all the airborne particles settle out. It will cover everything. A garage or driveway (weather permitting) is an ideal place to work. If that's not an option, cover up the things you don't want cover in dust with plastic if possible. Most importantly, keep the MDF out of your lungs and eyes. A basic set of protective shop glasses and mask can be had for minimal cost, like under $10.



Working on the side panels first. Use the nice straight and square factory edge of the MDF sheet for the back and bottom of the side panel. Squared off the top of the piece to 66-1/2" using a circular saw and a straight edge clamped to the piece of MDF as a cutting guide.



Cut out the paper template and tape into position on the sheet, then trace with pencil.



If anyone is planning a Donkey Kong build and needs the template, let me know. I can fold it up and drop it in the mail to you. Hate to just toss it away, might be useful to somebody.

[PixelPaul]

Time to start cutting. A jigsaw is the tool of choice to cut the curves in the front of the side panels. Used a "wood" blade on the jigsaw, make sure to make relief cuts so the scrap pieces fall away in smaller chucks rather than a single large piece that could break off.



Try to cut a bit just outside of the trace line. My jigsaw skills were a bit rusty, and the cuts weren't as good as I would have liked. The better you are at cutting the less sanding you have to do. After cutting out both sides, clamp them together for sanding. This will allow you to do both at one time and will provide a larger surface area that will make it easier to keep the edges square.

[jmike]

Looking great. I've always wanted one of those Nintendo cabs.
You know if you're serious about shipping out that template and if its still available, I'd be happy to take it off your hands. Been planning on building a Fix it Felix cabinet.
My kids love that movie. I'll PM you my info.


Thanks.
 

[PixelPaul]

Time to clean up my amateurish cutting. Tools used for this step are an orbital sander (for straight sections) a wood file (to smoothen rough sections) and sandpaper (for curved sections).



Edge sanding MDF is pretty quick and easy, took only about 30 minutes to smoothen out my poor cuts. A quick tip, you never want to sand the faces of MDF and remove the "skin", just the side edges.



I felt like I accomplished something today, two completed side panels!



Time Spent 2:00, Total time spent to date: 3:30

[wp34]

Those sides look great. 

Hats off to you for keeping track of your time.  I for one don't like to think about that when I'm working.   

[Slippyblade]

He's probably got one of those chess timers. 

**smack timer**
**start sanding**
**smack timer**

[PixelPaul]

He's probably got one of those chess timers. 

**smack timer**
**start sanding**
**smack timer**

Times are only guesstimates. Just curious how long it will take to complete.

[Slippyblade]

He's probably got one of those chess timers. 

**smack timer**
**start sanding**
**smack timer**

Times are only guesstimates. Just curious how long it will take to complete.

I'm just giving you a hard time man, no real offence meant.    I'm enjoying the build to be honest, I've run into a finances issue with my current project so it's on hold for a couple weeks.  Living vicariously and all that.

[PixelPaul]

I'm just giving you a hard time man, no real offence meant. 

No worries, I know you were just kidding.

[jdbailey1206]

Good start Paul.  I really need to update my thread.  I don't want to be out done.     I'm surprised AJ hasn't 'subscribed' to this thread yet.  I know you're there.  Somewhere.

[mcseforsale]

HA!

http://forum.arcadecontrols.com/index.php/topic,137041.msg1413856.html#msg1413856

AJ

Good start Paul.  I really need to update my thread.  I don't want to be out done.     I'm surprised AJ hasn't 'subscribed' to this thread yet.  I know you're there.  Somewhere.

[JDFan]

Just one small suggestion on the MDF panels -- Since Lowes and Home Depot will usually only do a couple cuts for free and aren't real happy if you ask them to only cut a portion of the panel like is needed in your layout posted. I'd rearrange it like shown in this pic so they can just cut the panel straight across at the 65.5" mark and then if you wanted they could make the second cut on that at the 33.375" mark again straight across the entire panel to get the entire side panels removed from the rest of the panel (rather than them having to cut and turn the semi cut panel.) leaving you 6 manageable size pieces to load in the truck !

[PixelPaul]

Just one small suggestion on the MDF panels -- Since Lowes and Home Depot will usually only do a couple cuts for free and aren't real happy if you ask them to only cut a portion of the panel like is needed in your layout posted. I'd rearrange it like shown in this pic so they can just cut the panel straight across at the 65.5" mark and then if you wanted they could make the second cut on that at the 33.375" mark again straight across the entire panel to get the entire side panels removed from the rest of the panel (rather than them having to cut and turn the semi cut panel.) leaving you 6 manageable size pieces to load in the truck !

Turns out that is exactly what I did, had a single cut made at 65.5". A 48" x 65.5" panels *just* fits in the back of a Ford Explorer with the back seats down.

[jdbailey1206]

HA!

http://forum.arcadecontrols.com/index.php/topic,137041.msg1413856.html#msg1413856

AJ

Good start Paul.  I really need to update my thread.  I don't want to be out done.     I'm surprised AJ hasn't 'subscribed' to this thread yet.  I know you're there.  Somewhere.

 

[PixelPaul]

Getting ready to start the cabinet assembly. In looking over the Jackobud plans, there seems to be a few missing dimensions. Does anyone know what these might be?



1. For the marquee light box shelf, how deep is it?

2. What is the angle that monitor is mounted at?

3. How far back is the setback of the monitor?

[SlammedNiss]

you wouldn't happen to be in the market for a monitor bezel vinyl, would you? I printed out a couple when I made one for a friend, so I still have the spare sitting around. Can do the side graphics too if you need those too.

[chopperthedog]

1. 22"
2. 40 degrees
3. The tube is 3 3/4" away from the bezel block and a tad higher. (see pic)


good day.

[PixelPaul]

you wouldn't happen to be in the market for a monitor bezel vinyl, would you? I printed out a couple when I made one for a friend, so I still have the spare sitting around. Can do the side graphics too if you need those too.

Thanks for the offer but not really thinking that far ahead. You have a great looking cabinet by the way!