Artwork Test
Before sending the artwork off for printing, I had Staples do a quick B&W print job of both the Marquee and CPO. I am glad that I did! After cutting and scotch-taping it on the cab, it looked like this...
You can see the problem, can't you?
The lunar lander is cut off. So I checked my measurements, and sure enough, I had sent BGoulette the wrong dimensions for the marquee (I think I must have measured it without the retainer in place). BGoulette quickly made a revision to the artwork and it is sent off to stpcore for printing.
Lesson learned-- Always do a mock-up before sending the art for printing!
Here is where I need the advice of you pros-- When the artwork comes back, how in the world am I going to make a perfectly round cut-out for the trackball? All the other holes have margin for error, due to being covered by the button rings and the joystick dust-washers. But how do you all cut out clean holes for a trackball in poly-laminated vinyl?Control Panel Mock-Up
I had some spare OSB laying around, so thought I should practice on it. I laid the original CP on top, traced it, cut with a jigsaw, and there it was. Note that I did not recess the trackball mounting plate, as this is just a test.
For anyone who might be getting the wrong idea, let me make something very clear-- You do not want to build a control panel out of OSB! This is great stuff for sub-floors and roof decking, but the inconsistency of the material does not make it at all suited for cabinetry.
Next I dropped in a long-shaft Zippyy I picked up on eBay to check the height. I read somewhere that the suggested height of the exposed shaft should be 1" between the control panel and the balltop. I tried it and didn't like it. Too short for my taste.
So I had to recess the joystick mounting plate in the underside of the CP. And this required taking apart the joys.
Here are the Zippyys-
Broken-down Zippyy-
Routed out 1/8" from the underside of the panel-
I know the serious builders make jigs for this sort of thing, but I find a steady hand and a clamped 2x4 does the job just fine. Now if this was on the top of the panel, you probably would want a jig to hit it perfect.
Screw in threaded inserts from the bottom...
Note on the threaded inserts-- This piece of OSB is 5/8" thick. The original CP is 3/4" While the inserts show through from the top of this test panel, they should be hidden below 1/8" of the top on the final panel.
And getting threaded inserts screwed straight into OSB is impossible, which is another reason you'd never use this for a real control panel.
After putting the joys back together--
And at this exact moment in time the DHL courier shows up and delivers my Ultimarc goodies.
Spent the next day drilling holes for buttons and wiring up the Ultimarc Ultimate I/O for controls and LEDs. Will get some pictures of that for the next update.