Metal Control Panel Question

[brained]

Hi i've got a dynamo arcade cabinet and it has a metal control panel with an Mk3 Layout.

[exibar]

no no no,PLEASE do not try and use that drill spade to cut metal with.  You'll wind up hurting yourself if you actually get through the metal with the tip of the spade.

  What you want is a Bi-Metal hole cutting saw.  Home Depot sells these.  You'll also need the arbor that it connects to.  The whole deal will run you less than 20 bucks.  

 Take it slow, wear safety glasses (you only have one set of eyes ya know!), and you'll be fine.  A drill press is best used for this, but you can do a pretty good job with a hand drill if you're not rushing things.

  To get the sheet metal, measure out the size of your control panel, then head on down to the metal supply company.   They'll cut the sheet metal to the size you want.  14 - 16 guage should work well.  14 might be a hair too thick now that I think about it with this going over an existing metal panel.  Try an 18 guage peice of galvanized sheet metal.  Galvanized sheet metal won't rust easily.  But you don't want to breath in the dust from it while cutting, wear a mask.

  Good luck with yor project!
      Mike B

[mmmPeanutButter]

Also I own a 1 1/8" drill spade, what shall I use for drilling that CP?

Try to get a greenlee punch.  It is extremely easy and will give you a nice clean hole.  I got one cheap on ebay.  Just keep your eyes open.  The 1 1/8 greenlee punch is a pretty standard size so you might want to ask around to see if any electrical conduit guys have one you could use.

(if you don't know how the punch works - drill a pilot hole (3/8?).  Unscrew the punch and slide bolt through pilot hole.  Attach other side of punch.  Use rachet or adj. wrench to tighten the bolt.  This will draw the two halved of the punch together and produce the hole.  Simple.)

[brained]

I've saw a restoration from Oscar, and he welded metal parts to cover up them holes. So I'll have to take this to some metal workshop to cover the holes.

Maybe if I use epoxy and metal bits to cover the holes, has anyone tried this???, or I'll just have to weld them in.... this is my main concern here... Please help me, I want to work with my cab!

BTW, thanx for the suggestions.... I'll look forward for using what you guys recommend. I'm also opened for new suggestions....

Metal panel sucks!!

OSCAR Where are you, I've seen that you made a Restoration of a dynamo cab. Any advice that you have for me??

[fredster]

If you put plexi over the CP, you don't have to fill them.  Just put the overlay on top.

You can also just use Bondo.  Put some backup tape behind the hole and fill it with bondo if you want.

Greenlee punch all the way.  You can get one for $30 at an electrical supply house.  Get the 1 1/8" punch OD for it. I use it on my metal CP's and it works great.

[exibar]

well, if you don't want to use the metal control panel, you could cut out large squared sections in the metal, and cover the whole thing with 1/2" MDF or plywood.  Then you only have the MDF to worry about, as long as you put the squared holes in the right location so you could fit your joystick and buttons in them.

  A $30 jigsaw from HomeDepot with a Bi-Metal blade will do the trick nice and easy for ya.  Clamp the metal down with enough overhang for the square holes, wear safety glasses as there WILL be little bits of metal flying around (and you only have one set of eyes <grin>) and cut away.

  Good luck, and remember take pictures and post them up!

    Mike B

[durak]

I'm in a similar situation so I'll just reply to this thread instead of making a new one.

The attached picture shows what I'm planning to do. The red squares are the areas to be removed, and the dots are places for screws. I'm going to mount an aluminium panel on top of it, the joysticks will take use of the old holes and the buttons are going to the removed areas. I think it will be quite solid. The aluminium panel will be done by a metal shop, what thickness do you reccommend?

I was thinking of cutting the squares with a dremel tool, but will metal saw be a better choice? I think at least with dremel it will take ages and lots of cutting disks..

[exibar]

I'm in a similar situation so I'll just reply to this thread instead of making a new one.

The attached picture shows what I'm planning to do. The red squares are the areas to be removed, and the dots are places for screws. I'm going to mount an aluminium panel on top of it, the joysticks will take use of the old holes and the buttons are going to the removed areas. I think it will be quite solid. The aluminium panel will be done by a metal shop, what thickness do you reccommend?

I was thinking of cutting the squares with a dremel tool, but will metal saw be a better choice? I think at least with dremel it will take ages and lots of cutting disks..

  The metal shop will be able to help out with the thickness, I'd say 16 - 18 guage Alum sheet would work for ya.  

  cutting the squares can be easily (kinda easy) with a Hack saw that can be bought at home depot for under 10$ with spare blades.  

   Mike B

[daeven]

Very good tutorial on metal CP repair:

http://www.tutankham.com/CPRESTO/cpresto.htm

I just fixed a Centipede with 8 extra holes in it using his technique.

[brained]

GREAT!!!!!!!! this is definitively great!!

This is what I was looking for, no welding, and truly DIY!!. Thanks a lot you're a life saver. Now I need to wait for the weekend to start.  

I think you should give that link to Saint. That's a really good one!!