Filler under too deep of a router cut?

[rackoon]

OK, I routed about a 1/16 too deep for my trackball plate (big grey industrial kind) and I need to raise it up with something that won't crack apart and I can ether squish down my plate into or feather over the top.

My 3/4" plywood CP has a large non sticky sticker from gameongraphixs.com that will go over the top and then have 1/8" plexiglass sitting on top or it all. 

Was thinking bondo or latex acrylic calulk.  Bondo is sandable but may crack. Acrylic latext caulk but can't be sanded. I even toyed with the idea of a thin coat of JB weld making a big washer like thing.

[leapinlew]

Isn't there something else you can cut to fit? Was thinking maybe some pieces of formica, tin, or something. Seems that would be easier than trying to get the depth right with bondo.

[Slippyblade]

I'd Bondo it.  If you are going to use a graphical overlay anyway, who cares if it cracks as it cures?

[leapinlew]

On second thought -

I might cut a new top. Not sure how complex that would be, but if you have the wood and a pattern trace bit, it's a 20 minute deal.

[MartyKong]

You won't have any problem with leveling out with Bondo.  I had a mishap cutting my T-molding slot. Bondo'd it up and recut with no problem. With that said leapinlew wins with the best suggestion

[rackoon]

I would just make another but this thing in done except for that and a t-molding cutter wheel mishap fix. I got hella hours in this bad boy.

What could I find that is 1/16 thick.

Also, what are you all using to fill in small gaps between routed out joystick plates and edges?  Bondo?

What happened was the trackball posts flare out when they meet the plate, creating a false sense of not being deep enough of a rout when you set it in. But flip that sucker over, drop it in upside down, and is quickly becomes apparent that I was correct the first time. Should have trusted myself. 

[Slippyblade]

Hell, if that's all it is...  maybe just layer some sheets of paper into the pocket to build up to the EXACT thickness.

[Jamesbeat]

I would just make another but this thing in done except for that and a t-molding cutter wheel mishap fix. I got hella hours in this bad boy.

What could I find that is 1/16 thick.

Also, what are you all using to fill in small gaps between routed out joystick plates and edges?  Bondo?

What happened was the trackball posts flare out when they meet the plate, creating a false sense of not being deep enough of a rout when you set it in. But flip that sucker over, drop it in upside down, and is quickly becomes apparent that I was correct the first time. Should have trusted myself. 

How about a 'gasket' type thing cut out of a sheet of plastic?
Something like a Folgers coffee can lid or similar? Nice and easy to cut with scissors or a sharp knife.

[n3wt0n]

If your error is 1/16" I would use 1/16" thick washers on the 4 bolts between the trackball mount and the wood. This would raise it just enough. If that isn't strong enough and allows the mount to bend then I would go with Jamesbeat suggestion and cut a gasket out of something that is the correct thickness.

[bluelight]

I messed up my t molding slot and used this stuff called wood filler to fix it. Worked very well and comes in little tubes. I couldnt find a small batch of bondo. Not sure if it would work for your situation but just figured i would mention it cause most people usually say bondo and dont mention wood filler.

[Jamesbeat]

Wood filler is good for some situations, but it can be crumbly. It might not last in a situation like this.

[rackoon]

I got a weird idea so tell me if I am way out on this. What would happen if I laid down a bunch of hot glue gun glue, place clingrap over it so it dont stick to the track ball plate, then squish down the plate to the perfect height.

[leapinlew]

I got a weird idea so tell me if I am way out on this. What would happen if I laid down a bunch of hot glue gun glue, place clingrap over it so it dont stick to the track ball plate, then squish down the plate to the perfect height.

Do that with bondo. It has more playtime. I don't think Hotglue will stay pliable long enough.

[Jamesbeat]

I got a weird idea so tell me if I am way out on this. What would happen if I laid down a bunch of hot glue gun glue, place clingrap over it so it dont stick to the track ball plate, then squish down the plate to the perfect height.

Do that with bondo. It has more playtime. I don't think Hotglue will stay pliable long enough.

Yep, bondo and a plastic barrier to stop it sticking to the trackball plate.
I'd suggest one of the 'rustly' plastic shopping bags, because they are polyethylene, and won't be attacked by the styrene etc in the bondo and should release easily when it's set up.

[rackoon]

Got a fat tub of Bondo on hand, so Bondo it is

Thank you gentelman 

I went with (for the first time) jlf joysticks instead of Happs and it adds a lot of extra work but I just wanted to do something different because this is my 6th can build.