OK, I spent about 5 more hours in the shop today, 2 hours last night. Here is the play by play:
First I layed out the structure for the top on the scale printout of the side. If I could offer any advice to anyone building a cab from scratch, it would be to draw as much out on a side with a computer (I use illustrator, but anything that allows you to draw to scale) and get it printed out on a large format printer. I am lucky enough to have access to one at work, but office depot, kinkos, staples, and a bunch of places offer printing services for technical drawings and it isn't that expensive.
I had already added the key measurements and lines on the drawing, but I hadn't taken the time to draw the full dimensions of the wood, so I did this first. This gave me a great template to make each piece. It was especially helpful on the angles.
I did the top structure first, the board that goes above the monitor with the speakers in it, the marquee light box (although I wasn't going to light this one, it would be a super easy matter to do), the top of the cab, and a piece in back just for structure. I got the 4 pieces cut, routed the speaker grill in, and started putting it together.
Then I lined it up on the drawing after gluing and nailing it together and it lined up pretty perfectly! You can't really see my lines I drew, but that's because the piece covered all the lines
I have seen a LOT of people using the same 2.1 Logitech speakers I used on my last cab and am using on this one. Here is the method I used to mount them: First I cut small blocks of MDF that are about 2" wide and just a little over an inch deep with about a 5 degree bevel on them (cut with a miter saw). I lined up the speakers, marked it, and glued and nailed the blocks in place. (yes, I missed with a few brad nails, just ignore them, they will never be seen and I was in a hurry, lol)
You can see I painted a little from behind to get the paint in the grill slots, this will help a lot later.
So here is a speaker next to the block:
And here is how it looks when I press fit the speaker on:
Since this will sit upright, the friction fit is good enough, but if I wanted to make sure they never came off even in transport I would just add one screw to each and they would be permanently mounted.
This morning I got started on the base. I am using corner casters this time, with adjustable feet in front. So where the casters are, I wanted it to be stronger since this is where the weight will be in transport, and it can take some good shocks. Oak, glue, and screws is about as strong a joint as you can get, and the corner made of oak could take a truck driving over it without breaking, so it should be strong enough to last. I cut the slots for the wheels on the table saw with a miter gauge, then cut the tabs out with the jigsaw. I had to open them a little more for the axels of the casters.
The top of the base doubles as the shelf the computer will sit on.
Wheels and feet are installed.
Now I cut the front of the lower cab out, and mounted it to the base. But I had to decide on the service door. My mom didn't care about a coin door, but I didn't want to do art on the front, and needed some kind of service door anyway, so I said screw it and cut the hole for the coin door. I will order it up and just take the hit (it is not in the budget). You just can't have an arcade cabinet without a coin door. The ones from x-arcade are $50 shipped and work with quarters.. I have found just the fronts without the mech for about $40-50, but heck it's the same price and you get the mech too, so I might as well.. If I could find a blank door I could stick a credit light on for $20-30 shipped I would do that in a second.
Anyway I went ahead and cut the hole for that.
Next I worked on the CP since it was easier to do it now rather than after the base was installed in the cab. The CP top and front is about an eighth inch narrower than the base.
And here is how it opens!
so with that done, I went ahead and started laying it all out on a side. Got the base and front lined up and glued and nailed. Then I got the CP base laid out and used that to get the keyboard door mounted and mocked up
Once that was all glued and nailed in, I got the top section lined up and mounted.
The next step took a while. My "bench" was just a couple sawhorses with the remaining MDF as a surface. It isn't perfectly level, so with the different sections all mounted to the one side, the other side wasn't going to just line up perfectly, and the thing is you have to glue it all at once. Furthermore, the sides are all curves and angles, and NOTHING just squares up to them.. This is where using battens would have been superior. Although things lined up pretty close on their own, I needed it to be perfect or it would be noticeable once it was all together. This was tricky but eventually I got my marks all set up and was able to glue it up and brad nail it to hold while the glue set.
So here it is, standing up and ready for the last couple parts before paint (keyboard door is off for paint, too much of a pain to remount it just for a pic, lol.) :
And here it is with the CP hinged open. I am VERY happy with this mechanism.. it is super simple, super stable, and looks good.
So the heat got to me and my girlfriend got an unexpected weekend off, so I am taking the night off, but tomorrow I will tackle the marquee mount, the bezel and monitor mount, the keyboard shelf and slides, and the back. I should also be able to get a coat of primer on it. Sides won't need paint, just primer because they are getting totally covered in vinyl, so I am just going rattle can this time. The setup and cleanup with the gun is overkill for the small areas, and I was very unhappy with the 2 month cure time on the latex paint. Mine is almost fully cured after 2 months, and it pisses me off, lol.