How to repair/rebuild a metal control panel

[OSCAR]

I recently picked up a converted Centipede cabinet that I will be restoring, and one of the first things I did was to rebuild the hacked up control panel.  Since a lot of people pick up old converted cabs for MAME projects, I figured some may find this useful.

So far the page only has the cp restoration, but as I do more work on the cab I will be updating this page:

http://www.oscarcontrols.com/centipede

[SaiNRuB]

Nice welds, you da man.


Looks terrific, great idea on using the washers to fill in the holes around the trackball.

[SirPeale]

I so need a welder (and welding experience) and an angle grinder.

[OSCAR]

My little MIG welder is the best investment I've ever made in tools, without a doubt.  I have a Millermatic 135 and it is perfect for someone that hasn't welded before.  Just a weekend of practicing on scrap metal to get the feel of it, and you will be turning out very nice welds.  Just like owning a router, once you get the hang of it, you use it for everything.

For example, I made my wife an artsy little candle holder to go with some of her Christmas decorations.  It only took a couple hours and I made it entirely out of scrap (and yes, you do see a spinner flywheel in there ).

http://www.oscarcontrols.com/tmp/angel.jpg



The washers were one of those "Ah-ha!" moments that hit me as I was digging through some bins looking for something suitable to fill the holes with.  The idea of cutting out metal discs with my nibbler was not very appealing...

Anyway, I'm glad you guys like the repair job!  Arcadeshop actually sells new Centipede control panels now, but what fun would that be?

[Zakk]

That's like a sign from above... I've had so many instances lately where a little bit of welding would save me tons of effort...plus watching american chopper has me all jazzed to weld stuff...I'm going to take your recommendation and get one of those puppies.  I've been doing a fair bit of resarch on the different kinds (MIG TIG etc) and was undecided.

 I remember when I plugged holes on my first panel, I used cut plexi, "liquid weld" and bondo.  It worked, but your method is just so much more 'right'.

 Nice work by the way, seems to be a lot of centipede cabs popping up around here.  It's such a damn nice looking piece of artwork!  Well, not as nice as that candleholder...

[Edgedamage]

I have been planing a metal desktop controller. The studio where I work is moving soon I should be able to get my hands on plate steel. Awesome work on that panel Oscar.

[crashwg]

Oscar, is welding an expensive thing to do?  I understand there's an initial investment of the welder, which you can most likely get down to the $150-200 range (if I'm not mistaken).  But I don't know what else has to go into these things to keep them welding.  Do they need some kind of bottled gasses, they obviously need some kind of metal rod thing to make the weld too, how much is that stuff?

Also, what are the differences between the types of welders; MIG, TIG, etc. (if there is more).

[Stingray]

they obviously need some kind of metal rod thing to make the weld too

Mig welders use a spool of wire rather than rods. Oscar is completely correct, once you use one you'll wonder how you ever did without it.

-S

[Minwah]

Lovely job Oscar

[Brax]

Looks wonderful.

Did the original centipede really have the button way up there? The middle of the far left mushroom seems like the intuitive place to put it. Is that the original location or was that becuase of your leaf switch?

Update: I just checked out klov.... That's really odd. The mushroom even looks like it was meant to house the button. I wonder if theres a story there? Maybe an Atari big-wig hated the position? Wierd.

[OSCAR]

Oscar, is welding an expensive thing to do?  I understand there's an initial investment of the welder, which you can most likely get down to the $150-200 range (if I'm not mistaken).  But I don't know what else has to go into these things to keep them welding.  Do they need some kind of bottled gasses, they obviously need some kind of metal rod thing to make the weld too, how much is that stuff?

Also, what are the differences between the types of welders; MIG, TIG, etc. (if there is more).

Be careful when getting into the lower end of wire feed welders.  El-cheapo brands & models have poorer designed wire feed units, which can lead to snarling up your wire, jams, inconsistent feed rates, etc...  All of these can make your wire feed welding experience nothing but headaches.  Two of the best known and most popular wire feed welders are Miller and Hobart and have excellent wire feeders.  I've been welding with my Millermatic for a few years now and gone through pounds of wire, but I've never had a single feed problem.  After the initial investment of the welder, the only real cost is the wire.  I bought a 10# spool almost 2 years ago, and I'm still using that spool & I weld at least a little bit nearly every day.   IIRC, I think that spool cost $60-$70.

I don't use a bottle with my MIG, I have been using it with flux core wire.  Using shielding gas allows you to weld thinner gage material without burn-through because the weld is cooler, and welding with the shielding gas is cleaner as it doesn't get flux everwhere.  However, on my Millermatic, I've found that it has fine enough adjustment on the feed rate and voltage that I can weld 20ga steel without burning through.  If you were doing body work or other detail welding, you would definitely want to consider using a bottle instead of flux core.  Check out rec.crafts.metalworking and sci.engr.joining.welding for more detailed info on this topic, there is far more information available there than I can write.  But also be sure that you understand many of the authors 'point-of-view' when researching welding and equipment in newsgroups.  Asking there if a $100 welder is any good is like asking about MAME in RGVAC.  


Brax - yes, the fire button definitely looks to be out in space up there, but that's where it was.  Go figure...

[OSCAR]

That's like a sign from above... I've had so many instances lately where a little bit of welding would save me tons of effort...plus watching american chopper has me all jazzed to weld stuff...I'm going to take your recommendation and get one of those puppies.  I've been doing a fair bit of resarch on the different kinds (MIG TIG etc) and was undecided.

 I remember when I plugged holes on my first panel, I used cut plexi, "liquid weld" and bondo.  It worked, but your method is just so much more 'right'.

 Nice work by the way, seems to be a lot of centipede cabs popping up around here.  It's such a damn nice looking piece of artwork!  Well, not as nice as that candleholder...

You will not regret picking up a little welder for your shop, that's for sure.  Besides, I'm sure MMP Products can always use write-off's...  

[Gumby]

How powerful of a welder does one need to do basic control panel repair?

You use a 135amp welder (a very nice one, but at $600 is currently out of range for me)..

The local Harbor Freight has this...

85 AMP, 115 VOLT FLUX AND MIG WELDER  

For mild steel, stainless steel, and aluminum. Weld with gas or perform flux cored gasless operations.

Welding current range: 25 to 85 amps
Input: single phase 115 volts, 60 Hz
Open voltage: 19 to 30
Duty cycle: 20% @ 75 amps, 45% @ 50 amps
Draws 21 amps @ 120 volts
Weldable wires: 0.023'' to 0.035'' steel and stainless steel, 0.030'' to 0.035'' aluminum, 0.030'' flux-cored
Includes: 2 lb. spool of flux cored wire, handheld face shield, brush hammer, fuse power line; Weight: 55.8 lbs.

For about $175

Is it strong enough?  Or do I need to go higher than 85amp for CP metal?

-Gumby

[crashwg]

So far the least expensive mig welder I've found was $299, from sears.  I'm definitly not willing to spend that much on something that I will probably not use more that maybe once a month.  Am I just asking too much for a good welder in the lower $200 range?

[Nannuu]

Hmmmm?  Why does my wife hate this board so much?  I really need a welder!  I have the same question as some others.  Harbor Freight has a mig welder on sale this week from 199 to 119.  Is that a total waste of time to buy?  My guess is yes as that seems to be the general rule - cheap tools = cheap tools.

[Tailgunner]

All you need to weld a panel repair in place is two car batteries, a set of jumper cables, and a few paperclips.

I did my panel repairs with a Miller TIG welder, but any of the small portable MIG machines should do the job.

[Rocky]

I am working on my first metal CP.

I tried an alternative method to welding.  I used "J B weld" instead.

I used it to cold weld a piece of metal under a hole and then filled it with bondo.  I also tried the fender washer thing that OSCAR did (man that's a cool idea!).  Both worked extremely well.  

Sand flush and you're done.  Everything is super solid. I had my doubts about epoxying those washers, but it holds fine.

So, if you don't have a welder, you can still cold weld.  It just take 12-15 hours to fully cure  

YMMV,

Rocky

[Rocky]

Close up of the fender washer after sanding flush

[Rocky]

Front of CP with 3 holes filled (2 with washers, 1 with bondo)

[Rocky]

back of CP

[Rocky]

CP painted black. You can still see the circles a little. It will not be noticable at all the the overlay glued on. They feel very smooth to the touch.

[Lilwolf]

Really great job!

I can't see using it on my arcade stuff (basically because...well...I have wood control panels... welding doesn't work well).

but very cool to see how you flaten areas up (weld metal over the back... and fill).   Makes sense... I thought it was more about cutting the right size patches..

Anyway... I would LOVE to get this for some of my cars... I always end up with old crap cars that could use some repairs...

But I don't have time for my arcade stuff... why would I want to start other projects like fixing up cars??

[2slk]

Nice job Oscar. The only way I found to get around welding myself was to befriend someone who works in an auto body repair shop. I'm sure if someone was really stuck for a small job and approached a shop they would be willing to help out for a small fee. They have great drills to cut button holes in a flash and can easily weld mounting screws as well.