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Cabinet almost finished - MAJOR PROBLEM #2 - (cpanel w/t-nuts) - I'm at wits en
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sofakng:
*sigh*

Yet another major problem for my first arcade cabinet.  I've probably spent very close to $1500 and I'm thinking the whole thing is coming out terrible.  The last major problem I had was with my three (yes, three) bezels...

My current problem is with my control panel.  I used a drill press to drill out all my buttons (according to my template and artwork) and today I started routing out the area for my joysticks and trackball.  I'm going to be using plexiglass so everything on top of the control panel must be flush.

So, first problem is I think I routed out way too much from the bottom of the control panel.  To make matters worse, I'm counter-sinking (with a 3/4" spade bit) my t-nut from the top so I can only guess how much actual wood is between the top and the bottom of the control panel where the joystick will sit.  To make matters even worse yet the t-nuts do not seem to dig into the wood.  I tried using a hammer to drive them into the wood but when I placed my artwork (which is sticky) it lifts the t-nuts right out of their holes!

To make matters even WORSE I can't seem to get my t-nuts to sit flush with the rest of my control panel.  When I placed my artwork down on top of the t-nuts some of them stick out, some of them are too far deep, etc....  I just can't win.

Check out this url here, it has many pictures of my problem:
http://s88181327.onlinehome.us/arcade/cp/

Right now I'm concerned about two things:

1) Making sure my control panel doesn't break when I actually go to use my joystick.
2) Making the t-nuts sit flush with the rest of the control panel so that my artwork sits flat on top of them.

Right now the artwork looks pretty bad when I place it on top of the t-nuts.  I was thinking about installing my joystick (into the t-nuts) and then using wood putty on top of them, then sanding, to make it look better.  I'm not sure if this is a good idea though.

If anybody has any suggestions please, please tell me.  I'll do anything at this point.  All I want is for this to come out decent after I spent all this money and time...   :( :( :(
Witchboard:
Okay, I'm looking at your... t-nuts... that just sounds wrong, but anyway.  Why are they not sinking into the holes?  It almost looks like you didn't drill the hole big enough for the t-nut shaft to sit in.  I can't tell, maybe I'm blind.  It also looks like you need to give them a little more room, like the countersink you made isn't big enough.  You could use a washer and bolt to pull your t-nuts down and make them flush.
bdsjake:
don't give up!  first time you are learning *everything* yourself.  You didnt' really expect to be perfect at it all?  No one can meet that standard.  

Anyway, I agree with witchboard's suggestion, use a slightly larger counter sinkbit, and slightly large bit for the actual bolt hole.

Since you've already routed out, there's only one thing to do, install a joystick and test it out!  the wood will probably be stronger than you think.

luck.
JustMichael:
I am wondering why t-nuts?  You could put carriage bolts through the plexiglass and control panel to hold the joysticks in place.  This will increase the strength of the material holding them.

If you don't want any bolts showing I would recommend using a forstner bit that is just slightly larger than your t-nuts.  Using these on a drill press you can easily control the depth by how far you turn the wheel to lower the bit.  Practice on scrap until you get the depth just theway you want it.  You may want the t-nuts slightly lower than the top of your control panel. This way you can fill the hole up to the control panel level or fill with "plugs" you made from scrap with a plug cutting bit and make sure to sand it smooth . Make sure to screw in the bolt before filling the hole with an putty type stuff so you don't get the bolt hole filled up.

As for as routing out for joysticks, I would actually recommend the tried and true hammer and a sharp chisel.
FractalWalk:
. . . tried using a hammer to drive them into the wood but when I placed my artwork (which is sticky) it lifts the t-nuts right out of their holes! . . . When I placed my artwork down on top of the t-nuts some of them stick out, some of them are too far deep, etc....  I just can't win.

Ok deep breaths. I think you've answered your own questions:

Step #1) attach your joysticks. This will secure the T-nuts and maybe even brng some of them flush with the CP.  They will never sit by themselves without being pulled down from underneath.

Step #2) For those that still stick out too high, just route out some more of the CP.

Step #3) Cover the installed T-nuts with a filler like wood putty and when it dries, sand it down smooth.

Step #4) Apply artwork.

If you are worried about the width of the wood after all that routing, I would delay step #4 and just play with the CP a while. If it holds up under your testing, you're proabbly good to go.  FWIW, the CP would have to be be pretty thin to pull out a joy during gameplay.
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