So I’ve been working on the board access panel for a couple of weeks. I’d say it’s about 90% done now. I am still debating getting some soft cabinet downs for it so it opens a bit more impressively. Additionally there will also be artwork on the inside.
I actually cut a panel at the same time I made the new kick plate, but it had been setting in the shop for several months. Finally I got around to finishing it. Sure I could have just painted it black but what fun is that? I mean inside here is where the boards are going to live! Still haven’t decided how they are going to be mounted, but at least their home and their front door will look nice!
Laminating all sides is a bit tricky, need to start with the sides. I am really sucking at documenting everything with pictures, but hopefully you get the idea.
I bought some drop hinges for the panel, but wasn’t really sure of the best way to cut the mortises. Ultimately I decided to just bite the bullet and use a forstner bit in the drill press. As it turns out it worked flawlessly. I also drilled a hole for the lock and widened one side to the correct shape for the barrel lock with my router; I then flipped it over and flush trimmed the other side to mirror the shape. I got lucky with free handing that and lucky with the mortise placement too! I guess the drill press does have fine adjustments for x axis and y axis, but I should have measured and marked better. As it turns out my eyeball is pretty good….
Or so I thought! Of course I had too much confidence when I cut the corresponding mortises on the cab bottom. I just used the forstner bit and my drill. I marked it with the hinges attached to the access panel but I disproportionally accounted for the gap on each side. It looks okay in this picture but it’s about an eighth of an inch off. When I mounted the panel it was sticking on one side (scraped the T-molding pretty good too). There’s also a pretty noticeable glue remnant that just won’t do.
As my dad says it was time to, “lick my calf over,” which apparently means to restart something, especially due to an error. You can see where I sanded off the glue and did other surface preparation. Now it was Bondo time! I sort of flirted with the idea to start this in the house but it wasn’t going to happen, that stuff is super toxic fumy! This was my first time to use Bondo and well, there was a bit of a learning curve. Maybe I never got the proportion on the hardener right, but that 15 mins to work with is some ---That which is odiferous and causeth plants to grow---! Still I got it done and after sanding the holes were filled nicely (that’s what she said).
I’d like to point out the authenticity of my cab here, I mean how many of you can say you have actual arcade chewed gum on the bottom of your cab? I also found an interesting token in the bottom. I’ll have to take a picture, the history of these things and where they have been is something that I have always found intriguing when watching someone do a refurbish.
While I had the cab outside with the kick plate off, I decided to fix a few other things, I never actually got the power panel opening square with my oscillating tool, so I put a straight edge inside the cab and used a flush trim bit on the router to make some adjustments.
Once the Bondo was good and cured, I carefully measured for the floor panel mortises, and did much better this time. Friday night I painted some of the interior of the panel area, and yesterday I installed the access panel. Here are several shots from the inside and out.
Thanks for watching, this is the last bit of structural work, short of the actual board storage solution which I still haven’t completely worked out yet. Tune it next time to watch me modify the JAMMA switcher. Also the wheels might slowly be beginning to turn on artwork, can’t wait until I’m able to give an update on that.