you got a website yet? if so i want to see it, cuz im trying to make a trackball like yours and i need a little help on it. or at least some more pics!
No website. Here's the rest of the pics I took, ask away if you have questions.
I used regular auto body bondo to fill all of the holes since I had some laying around.
Same thing for the trackball. I used a highball zinc mounting plate from happs. I traced the outline in the center of the panel, then routed down 1/8th of an inch, cut out the center with a jigsaw, laid it down, bondo'd the top, sanded down everything with 400 grit (used an air sander, but electric will work too). I was going to paint it, but since it's going to be covered up, I left it as is.
I laid the CP upside down, clamped a piece of plywood underneath, and sandiwched the plexi between the CP and plywood. Then used a router with a template bit and just dropped it into the holes, moved it around, went on to the next one. Finally, used the same bit on the outside edges, and was done.
For the trackball hole, I had to use a hole saw. I had no problems going slow with the drill.
I'm tempted to redo it again and move the start buttons to the sides, and redo the artwork again. I'll probably leave it as is for a while, and maybe get some new buttons. For the artwork I used photoshop and literally measured out the CP, found the center of the trackball, and used photoshops rulers to center the image on it. It worked really well, I was surprised. Then I just centered the artwork on underneath the plexi, and used a new razorblade to cut the holes out.