What to do about metal plate in CP top?

[JoeStrout]

OK, I set out this morning to do what I thought would be a simple task: cut four more button holes in the control panel I got with my old Gauntlet Legends cabinet.

But it turned out to be not simple at all, because there is a metal plate in there, between the plywood and the plexiglas.  The CP decal is stuck to this metal plate.  Here's a picture of it partially drilled through:



With enough patience, and stepping up through several sizes, I was eventually able to drill through it.  But my attempts with the hole saw were unsuccessful, despite trying a range of speeds and quite a bit of patience:



So then I thought perhaps I should just pry the metal plate off.  But I didn't have any luck with that either.  I managed to wedge it up a bit in one corner, but couldn't progress any further; it appears to be quite firmly glued down.  For completeness, here's a shot of the whole CP, with the plexiglas off; you can see that the decal wasn't perfectly positioned, and lets the plate show a bit in the front-right corner.



So, what to do?  We're considering these options:

• Get a better hole saw and more patience, and just keep cutting.
• Try harder to pry the plate off the plywood.
• Throw out this CP top and make our own from scratch.

Keep in mind that my woodworking skills are quite meager.  I might be able to cut a straight line, with enough attempts, but I have no idea how I would do rounded corners, or rout out the recesses for the joysticks, etc.  So, option 3 doesn't look very viable to me.

Any advice?

Thanks,
- Joe

[Nephasth]

The plate is held on with studs. You'll see little nuts on the back side of the cp. Take the nuts off and the metal plate will come right off.

[JoeStrout]

The plate is held on with studs. You'll see little nuts on the back side of the cp. Take the nuts off and the metal plate will come right off.

Ah, so it does.  I didn't notice them because they are serving double duty as the bolts that hold on the latch brackets, the top metal fits-against-the-bezel thingy, the hinge, and... the joysticks.  How did I not notice the joysticks were attached to the metal plate?!?

So... I'm bolting that plate back down, and going to Home Depot for some lube and a better hole saw!

[yotsuya]

So... I'm bolting that plate back down, and going to Home Depot for some lube and a better hole saw!

There's a Castle Boutique Superstore off 1-17 and Northern that would be a better place for lube than Home Depot. Ask for Tejano Jim.



Oh wait, you meant for the drill.....

[JoeStrout]

Yes, quite.  I watched some internet videos and learned that when metal is involved, things could get hot quick, so it's best to keep your drill well lubricated.

Anyway...

With a fresh bi-metal hole saw, some 3-in-1 oil, and a lot of patience, I was indeed able to cut the holes I needed.  It took almost two hours for four holes... but I was getting faster with practice; the last one took only about 15 minutes.

I'll post pics tomorrow... the day has completely gotten away from me, and I still have 200 kanji reviews to do!

[Nephasth]

It took almost two hours for four holes... but I was getting faster with practice; the last one took only about 15 minutes.

Jesus tits! Use a drill press. Less than a minute a hole. That metal is not thick by any means.

Less than $4 shipped for a proper hole saw.

I have a self collected "set" of those hole saws. And for sheet metal, there isn't much need to lube the bit. It's thin ---steaming pile of meadow muffin---. Now when you're drilling thicker metal, yeah go ahead and throw a bit of oil on the bit with each hole.

[JoeStrout]

I couldn't fit it in my drill press, nor is the surface flat (perpendicular to the drill axis), though had I known it was going to take two hours, I might've spent the extra 10 minutes to remove the hinge, hardware bits, etc.  Then I might have been able to use the press.  But when I started, I wasn't expecting it to be so difficult!

But no matter — it's done now.



And here's it is, all cleaned up and with the hardware reinstalled:



Slowly, painfully, but steadily making progress!