confused about top mounting joysticks on wood

[ac]

I'm building a cabinet for the first time, and I'm confused.
I purchased the t-stick plus from Ultimarc.  I want to top mount it without any
bolts showing.  Here's what their website says about mounting:

...these sticks can be mounted from the top of the panel. You will need to rout out a rectangular section to recess the faceplate. The faceplate, mounting bolts and plastic masking washer should all sit under a control panel overlay. The overlay just has one small hole for the joystick shaft.

I understand the way routing works.  If I rout out deep enough for the faceplate and bolt heads, it looks something like this:

Code: [Select]

Sorry for the poor ASCII picture

'                  U
'                  U
'                  U
+++++++++++++++++++U+++++++++++++++++++++++
##############o    U    o##################
##############-----------##################
##############|##%%%%%##|##################
##############|##%%%%%##|##################
              =  %%%%%  =
              |  %%%%%  |

"U" => stick
"#" => wood
"+" => overlay
"-" => faceplate
"o" => bolt heads
"|" => bolt
"=" => nut
"%" => joystick assembly
Its the overlay that I'm confused about.  Doesn't this create a pocket of space under the overlay?  Won't that pocket be kind of flimsy feeling?  Or is vinyl sturdy enough not to notice?  Also, I'm guessing the hole needs to be larger than the one in the "plastic masking washer" because at the height of the overlay, the stick needs to travel more.  (actually, with the "plastic masking washer" right against the faceplate, it moves whenever you move the stick)

It seems like I've seen a lot of control panels with the "plastic masking washer" on top of the overlay.  Do those get attached to the control panel, or are they just on there loose?

I've done a lot of searching for examples of this, all I ever seem to find are pictures of finished control panels, or vague descriptions.  I guess I can't figure it out.

AC

[CitznFish]

if you use a vinyl overlay you generally put plexi on top of it. This eliminates teh flimsy bit you're worried about.

[patrickl]

If you use an overlay that is supposed to go on top (with no plexi covering it) then you have to put something over the hole yes. I have seen OSCAR use plexi (or lexan) underneath the overlay. I used a thinner bit of MDF that I had (think it was 9mm)  Overall the top can't be too thick cause otherwise the screws for the buttons won't work anymore.

[GGKoul]

You dont have to top mount the joysticks.  I countersunk mine and I have no issues.

-GGKoul

[exian]

When you counter sink the bolt head what do you used to fill the holes in before you put the covering on?

[JesterDEV]

You could use a epoxy that hardens into plastic. Once it's hard just sand it down till it's flush. There is also a glue I think it's called wood filler but don't qoute me on that. It's a glue that you can use to fill holes in wood. It's easier to sand then the epoxy (allot easier) and you may be able to pop it out later.

If you want to change out the sticks later you just unscrew the nut (as the bolt wil be held in place by the glue/epoxy) and slip the grommit (?) off.

[patrickl]

When you counter sink the bolt head what do you used to fill the holes in before you put the covering on?

You don't countersink the bolt head, you countersink the t-nut. Drill a hole in the top, big enough to hold the t-nut flange. Slam in the t-nut and screw in the bolt from below.

Your home shopping store should have the stuff to fill the holes. I guess it's called filler (I only know the dutch word for it)  The t-nut is stuck in the wood by the nails so you don't need anything strong to hold it. Just something to fill the hole. Make sure it's something that doesn't shrink too much. So use a filler type that's for "larger holes".