Project: Mass-Replicate

[talkgeek]

Been a little concerned about whether I should post on our latest project  …partly because there is such good bespoke work done on this site, that I feel our work to be quite pedestrian / basic, and partly because this is more about mass manufacture than quality single builds….

But as friend of mine pointed out, there may be some value in sharing the process for any other poor schmuck that finds themselves in the same predicament…

So first some background…
I live/work in Wellington (New Zealand) and my brother-in-law resides just outside of Palmerston North – a 2hr drive north from me. – Like most mates, we talk once or twice a month – might text or email a couple times in between (so a lot by guy standards)

We both got the arcade bug a few years back, and before we knew it were restoring machines (note: I use this term loosely, when viewing the level some go to on this forum) with no available space let to house them – so overflows started showing up at friends (often normally not cleared with the partner  – some never got out of the van  ) or got sold, and then we found ourselves renting a few out to pubs and clubs etc, of course this all just helped to continue to fund our “bad” habit (catch 22).

…anyway in the last couple of years getting cabs in any type of reasonable condition at a reasonable price started becoming hard (as did working PCB’s), so we started to build from scratch our own basic designs (word of mouth [mostly our own] commissioned).

..anyway leading up to Christmas 2013 we both had some conversations with some friends / work colleagues and a pub re building some uprights (we had really only being doing our own Cocktail cabs designs until this point) – a quick check with each other and realised we were up for building 6 machines

Not a problem [wait for it] – we figured if we started building after New Year’s put 4 or 5 good weekends in we could prob have them completed by end of Feb. 

I was given the task of coming up with the design, cutting pattern (to cut down rework re setting up table saw / router etc) and artwork
My brother-in-law got pricing on materials, collected and cleaned out one of the sheds at the farm (father-in-laws) so we had a place to work (without having to juggle any of our other collective projects)

3rd Feb 2014 we meet at the farm and worked on the side templates and put 2 mock-up builds together

[talkgeek]

To be fair, I wasn't enamoured with the low-boy side template

its design was driven by trying to get 2 sides out of one length of MDF (actually 1 half side of a 1200x2400 sheet) 600x1200mm

I was wanting to chuck and start again, but my brother-in-law convinced me to try putting it together before starting from scratch

He was right, once it was together I didn't hate it (but don't love it either)

[Louis Tully]

.

[talkgeek]

– having a coffee that afternoon we started to talk about what themes these machines were going to have ..it quickly became clear that we were building more than 6 arcades

– in fact we had assumed we were talking about some of the same friends, when in fact they were completely unrelated, and to make it worse there was 2 pubs not 1 – in fact we needed to build 11x arcade machines (1 of which was Low-boy)

Gulp!

[talkgeek]

So.. this story isn't really about the cabs we are building (though here is a chance to contribute ideas on themes, because I don't have 10+ in my head, and my brother-in-law is pretty artistically / aesthetically challenged (great on the carpentry tools though!) - it's about mass manufacture of (now  ) 12x arcade machines inside 11 weeks (2 weekends of which are consumed by my daughters wedding - preparation and execution [Freudian slip?] ) 


As you can image.. theme planning was put on the back burner, while I went back to the computer and re calculated the material need and to see if we could optimise the cutting plans.

more to follow tomorrow (being called into another wedding planning meeting  )

[talkgeek]

To be fair, I wasn't enamoured with the low-boy side template

its design was driven by trying to get 2 sides out of one length of MDF (actually 1 half side of a 1200x2400 sheet) 600x1200mm

I was wanting to chuck and start again, but my brother-in-law convinced me to try putting it together before starting from scratch

He was right, once it was together I didn't hate it (but don't love it either)

   You're crazy. That lowboy looks badass. What kind of theme are you planning for it?

Thanks for the feed back - please contribute any theme ideas you have,

I always wanted to do a Moon Patrol theme, but really want that to be on the proper cab shape, we also have several marques (1943, MK2, Street Fighter, P.O.W, Chopperlifter, DonkeyKong, Area51, Punisher etc) on the shelf, so probably should use those - but can't help feeling they should be their correct cab shaped machines not on custom (new) builds

We are going to use a mix of vertical (60-n-1) and horizontal (485-n-1) multi-game JAMMA boards (yes sorry - we are using 19" and 22" 4:3 LCD monitors, but will use scan line generators) - accept this will mean a lot of people will now tune out, but reliability and power consumption are some of the drivers for these consumers

[404]

i really like the lowboy. Its not every day you see a lowboy with those kinds of curves. Typically lowbows you see are minimalistic in both design and outer aesthetics (paint, vinyl etc). IMO, this thing is screaming for a loud paint job of some kind.

[talkgeek]

i really like the lowboy. Its not every day you see a lowboy with those kinds of curves. Typically lowbows you see are minimalistic in both design and outer aesthetics (paint, vinyl etc). IMO, this thing is screaming for a loud paint job of some kind.

Thanks for the feedback - you seemed to be aligned with my brother-in-laws thinking, and given we are actually going to build 3 low-boys now (and the 10x uprights - yes we are up to 13 machines ..I'll explain soon), i'm def happy to try some extreme themes on a couple

for clarification: 2 of the uprights are for us, rest for customers (renting & buying), 1 of the low-boys is for a friend - the other 2 are ours (though not sure if i'm going to keep mine) - that's how we have now got to 13machines  .

Given painting is the part of the build process that normally takes the longest time (we outsource this work to my father-in-law - he has a full-on paint booth which he uses because he restores old cars [mostly Ford's], more on that later) I had been toying with trying out just using Vinyl as a replacement for the last 2 top coats (so just apply sealer, and 1 top coat then vinyl).

The Vinyl I have used up until now (just for artwork) is 3-5year exterior sign-writer grade 3M or Avery brand stuff (lasts a lot longer when inside) - but there has been a bit of a trend here with the younger market lately to use a 3M exterior auto product on cars, which i'm keen to try [on arcades, not my car's  ) hard wearing / suspect longer life internally, easier to install - if you believe the "bubble free" marketing 

I had already ordered a couple of vinyl's to try - a carbon fibre look (which I really like) and a Chrome Red (which at the moment looks more like that foil wrapping paper you can get for wrapping xmas presents) - my plan was to use these on a couple of the consoles (base starting point) - my brother-in-law saw the Red Chrome and immediately wanted it all over a Cab with silver T molding and some sort of racing theme (might even have a go at making his low-boy a stand-up racer....)

 

[emphatic]

The lowboy is superb. Keep going, please.

[amendonz]

Palmerston North represent. 

[talkgeek]

So we procured an additional 10 sheets of MDF (and they chucked in an additional one as packing - score! - which we'll use for internal framing, wasn't hardly marked anyway) - also ended up getting better discount, which they also removed from the first 10sheets as well double score!

Sheets are actually 1220mm x 2440mm x 18mm the cutting plan was worked out on paper once I realised I didn't need to account for the 3mm waste from blade cut in the original measurements (will update visio diagram and then post) - believe or not this equated to saving 2 sheets of MDF over the whole process (hence addition of another 2x low-boys) -note some of this was in the way we changed the marquee section so the back door didn't need to go the full way up.

First whole day was spent cutting sheets in half (so more manageable, and then cutting all the main components (even with an extractor fan and suction fan on the table saw, we looked like we had been swimming in sawdust - masks and goggles an absolute must with this stuff! - apparently its nearly 60% glue, so not good for the lungs.

[BAMBOO]

Who cares about the arcade, look at that awesome wood shop you got going on there.  Thats an arcade hobbyists dream. 

Now I feel like a slouch for doing my work in my arcade room.  Only place I can work on my cabs.

 

[talkgeek]

Something to note: We already had 1 sheet of MDF, which we used for creating the side templates for both the upright and the low-boy - so the templates don't figure in the above materials.
but if you are keeping count - we are building 13 arcades out of 22 sheets of MDF, basically each cab is costing less than $50NZ in MDF to build (we can't get stuffed/ugly/empty cabs for twice that in this country makes no sense)  including the side templates (which we can reuse again - though suspect after this we won't want to build any more in this shape.

Tip #1
1. Create the side templates (upright and Low Boy) - these won't even be used in a cab, they are used as a pattern for the router and the drill hole locations
2. Use these templates to then create the sides (draw around template on source sheet, then jigsaw 5 to 8mm out from the line to remove waste, then clamp template to side and route around using the template as the guide) for the first build machine (which test the build process / so you can make alterations BEFORE cutting out everything and potentially wasting material.
3. Start building your first machine - but first use the template on the first side to workout where all the drill holes are - then use that template to pre-drill all sides from that point.

tip #2 (same rule if 1 cab or 13+ )
Cut all the related sections at the same time on the table saw - ideally don't move back and forwards between sizes.
  e.g.
1. We cut all 21 full sheets at the same time (in half, including removing waste) so everything was 600mm deep (all exactly the same) resulting in 42x 600x2440 sheets
3. we cut all sides (26x 1800x600) - leaving 26x 635x600 sheets
3. we cut all the kick plates (13x 780x600) - leaving 13x 1655x600 sheets that we used for back doors and framing etc
4. cut all relate framing/console sections at same time  (52 x 200x600 and 52x 150x600) from the left-overs from the sides etc
etc

boring as all hell - but everything completely matches this way, no having to shave a mm or so off here and there.. to get things to line up

..as I said, somehow we ended up saving 2 full sheets (4x 600x2400) which we are going to use to make an additional 2x Low-boys

We also have some 10x 600x600 sections left over as we scored some (7x sheets) 6mm x 1100x1400 Perspex quite cheap (cheaper than we pay for a 3mm x 1200x2400 sheet), so plan is to use that as the bezel front with framing behind (vs using MDF as support with 3mm Perspex in front) and for marquees - this assisted is saving the extra MDF sheet.

I'm also using some of those 600x600 sheets to create a coffee table arcade for a work colleague (so I guess we are up to 14 arcades  - yes this is getting ridiculous ) - but that will be a separate project and not until this one is finished and the only reason i'm doing this is he threatened to build this    hell no! 

[talkgeek]

Who cares about the arcade, look at that awesome wood shop you got going on there.  Thats an arcade hobbyists dream. 

Now I feel like a slouch for doing my work in my arcade room.  Only place I can work on my cabs.

 

If its any consolation - my personal projects are done in my arcade room / home office or on the deck (when wife's not around) this "workshop" is a 2hour+ drive from my place - so requires planning (and permission  ) to go there 

..but yes, feels pretty sweet once we are there 

[talkgeek]

 

[Generic Eric]

Thanks for sharing the layout.

[talkgeek]

So back to the build..

When you're only doing a machine at a time - hand router works fine, especially for T-molding if not a bit slow, fiddly and you will make mistakes (F2 and liquid nails are my friend)

however building 13 machines meant a slightly different approach - so we built a routing table (actually out of a failed cocktail build - nothing is ever truly wasted) and got a cheap router from local DIY shop http://www.bunnings.co.nz/ozito-router-850w-_p00226237 $82NZ and pulled it apart and fixed it to the table

When then used this to do the T-cuts on the mockup upright and lowboy builds - while it worked well for the lowboy - the tabletop was just not big enough for the upright sides, and we created a few wider than desired T-cuts due to not being able to keep it flat (also means T-molding won't be centred when being applied  )

So we used the waste cuts from the screen section of the side panels to extend the table router top - really  bodgy looking - but worked well.

[talkgeek]

Recap - cut all the pieces needed, routed out the side shapes, then T-Cut the sides (26), console front (13), speaker mount bottom (10) and Bezel mount top (13)

now we finally start to assemble something

1. Console unit (2x pieces x13 = 1.5hrs)
2. Marques unit (4x pieces x10 = 4hrs)
3. Kickplate, base and coin box (8x pieces plus reinforcing for wheels x 10 = 4.5hrs)

Then we put the battens on the table (this is to bring the back up the depth of the mdf (18mm) so as to allow for back door to be flush when added at end of build)
1. Placed first the Kickplate complete bottom section on and built a jig to hold in correct place, then fastened first side to it
2. The did same with marque section - made jig to hold in correct place, fastened to side
3. Rotated cab (ideally should have worked on other side - but garage just now to full to do that) and fastened other side to cab components
4. then added other internal struts (console shelf, PCB shelf etc)
5. Add console to cab

..and that was 5 cabs assembled inside 2hrs 

[talkgeek]

just as we are putting Number-5 (hey there's a theme in there) cab on the ground, the father-in-law walks pasts and enquires if we are building Arcades or coffins  ..... heathen!

..so that's it for the next 2 weeks  disappointing to get to this stage and then having to hit pause ....doubt will even get some stress relief in (game time) 

[talkgeek]

Have been quite remiss in keeping this up to date, Daughter's wedding, weather and changing job (requiring a lot over travel) hasn't helped 

oh.. and picking up 3 extra cabs for restoration (and play .. but more on this later)

..anyway will try and play catch up over the next few nights

Filled and Sanded 4 uprights, fitted backs and damage rails, and then applied sealer (needed for MDF) and 3x top coat satin black.

[talkgeek]

We had been conscious to try and keep the weight down on these cabs (hence slimmer design etc to allow for the fact we often find ourselves having to moves these machines between customers on our own). so I was a little worried about their strength / rigidity.

Turns out I shouldn't have been - these things are as tough as old-brick-sh!t houses - this is all that happened after [accidently  ] dropping one of the front-end-loader on way back from the painting booth  - it fell nearly 2.5metres onto it's edge, and this was all the damage there was (didn't even crack the paint in the joints).

.. of course the cabs still a right off    but at least we know they are more than strong enough for the moving around they'll get over the next decade or so..

[talkgeek]

After the painting process I applied the base Vinyl cover to the sides - this cabs going to have a Captain America / Shadow Avengers theme

I lay the vinyl over the side of the cab and then pin the centre with 3M masking tape (doesn't damage paint but holds the vinyl in place (cab is 600mm wide and vinyl is only 620mm wide, so really easy when applying to go slightly askew and waste nearly 2metres of vinyl)

I then lightly cut through the backing (in centre) and peal it back - then using the squeegee move back and forward (from the front) applying the vinyl from the middle to the bottom (taking care to get all the air out), pulling the backing off further as I go - if you take your time the end process looks better than any paint job you can do (unless you're OND of course)   

Once middle to bottom is done, I then do Middle to Top (reason I do in this order - is doing the top first has more chance of skewing the vinyl while applying, which means when you go to do the bottom you can find the skew is enough to no longer cover the sides completely.

[talkgeek]

unfortunately I was in a bit of a rush to get the console together (so we can test  ), and didn't take any pic's of applying the Carbon-Fibre looking vinyl (was a dog to put on, took 2 of us, one holding it tight, while the other was massaging it on to the console - its car vinyl and is a lot tougher / harder to use than normal, but came out ok)
 

[wirenut]

Oh man I love the sleek design!  It is so clean.   

[talkgeek]

Oh man I love the sleek design!  It is so clean.   

Thanks heaps - loving your project too! 

[talkgeek]

Last pic's for this cab
Added Avengers logo to top sides of cab
back painted Perspex bezel with Tamiya modeller's Black PS-5 paint [spray Can] on recommendation from OND [thanks heaps  ]
Bezel turned out excellent, I rounded the corners and outside edge sit's inside the LCD screen frame - almost gives the screen a CRT look to it - shame my photo skills haven't produced an image showing this 
 
Still to wire up coin mech, fit a SLG, polish bezel front (some abrasions from moving around on table saw during cutting process - Brasso and Dremel with polishing head will sort that) and full 2 player testing process   

- but I'm calling this cab finished.

on to the next 11 

[SpaceHedgehog]

I can't believe you're building 12 of these 

The design and finish looks great.

[talkgeek]

I can't believe you're building 12 of these 

The design and finish looks great.

Thanks for the feed back
 
I can't believe we are doing 12 of them either  - halfway through and thinking it was a bit stupid to be honest especially given I have 3 projects [restores] of my own to work on - Taito upright, Moon Patrol and Sega Megalo 410 [now a MAME Project using 32" LED Screen]

Here are pic's of another cab (will take pic's of other 4 once I get back in country / up to farm) - note: this isn't the correct Marque (have an SFIII one coming for this cab), and while it's not obvious from the photo's - the base blue vinyl on the 2 cabs is different, Avenger cab is lighter than that of the SFIII cab

Seeing as there was more interest in the Low Boy cab, will prob finish this thread once I have got one of those completed.

[talkgeek]

Need some help from forum members..

Anyone know where to find Spinners that will work with JAMMA boards ? (not USB / MAME)

All my searching has only thrown up these suppliers which are USB based 
http://groovygamegear.com/webstore/index.php?main_page=product_info&cPath=86&products_id=268
http://www.arcadeworlduk.com/categories/Arcade-Parts/Spinners/

thanks heaps for any responses recieved

[brucelee00]

Awesome job on the cabs I love how the CP flips down on this upright. The paint job and vinyl is awesome on these very well done 

[talkgeek]

Awesome job on the cabs I love how the CP flips down on this upright. The paint job and vinyl is awesome on these very well done 

appreciate the nice comments - thankyou

[RandyT]

Anyone know where to find Spinners that will work with JAMMA boards ? (not USB / MAME)

All my searching has only thrown up these suppliers which are USB based 
http://groovygamegear.com/webstore/index.php?main_page=product_info&cPath=86&products_id=268

I've made special versions in the past for folks with non-PC hardware, and they have reported that it works great.  Email if you need more info. 

[mgb]

These cabs are looking great.
very fine job 

[brucelee00]

Just out of curiosity as I am nearing the paint stage as to what sealer you used ? and any recommended primers ? Thanks

[talkgeek]

Just out of curiosity as I am nearing the paint stage as to what sealer you used ? and any recommended primers ? Thanks

Sorry for delay in responding, been out of country for last few weeks on a couple of projects

re MDF we use MIROBILD AC 3720 Pigmented Undercoat (White or tinted with Black) http://www.mirotone.com/Live-3720/default.aspx
and then use 2 (if vinyl over top) or 3 coats of Satin MIROBILD AC 3770 http://www.mirotone.com/Live-3770/default.aspx

If small jobs (e.g parts / small restorations etc) there is another product from White Knight (Australian Company) called MDF Primer that I paint on using a foam roller - typically dries in less than 3 hours, but I normally give a 2nd coat on any edges then sand before top coats
 

[talkgeek]

We picked up another distraction last weekend, we seem to be finding reasons not to stay focused on the remaining 6

Plan to get to at least one of the low boy cabs soon - meantime some picks of our new toy 

We are planning on rebuilding / separating into 2 cabs (vs the large cab it currently is), intention to rebuild like the USA manual we have for this cab, and also to make it easier to move around.

Bonus during "testing" discovered it had the rom update and so had extra cars and 3 extra tracks (6 in total)