Control panel plan of attack

[kspiff]

Well.. I should be starting on my control panels soon (laying down the art + lexan, drilling the holes for buttons/joys, etc.) and was wondering if this sounds like a good plan:

1.) seal or Kilz-coat (would I have a harder time applying artwork to one as opposed to another..?) control panel tops, seal bottoms
2.) apply (slightly oversized) artwork to control panel tops, trim (slightly oversized again, so as to wrap around a bit)
3.) apply (slightly oversized) lexan, drill holes through lexan and CP for bolts, secure and trim lexan (would a 3-flute router laminate trim bit or 2-flute flush router bit be best..?)
4.) drill button and joystick holes with drill press and 1 1/8" hole saw

Now I know I want to drill the lexan, artwork, and panels at once (to avoid blowout and make sure the holes line up perfectly -- I would suppose the artwork won't get roughed up much by this..?), but should I hold off on applying my artwork until after I get the lexan trimmed since it will wrap a bit?  Rambling..  

Also, what to print on again for this?  Adhesive-backed vinyl?  Does this look good without any further preparation (laminating, clear-coating, etc.)?

kspiff

[Smittydc]

AHHH!   I would definitely not drill the artwork -- I am almost positive it would get scratched if not altogether destroyed.

I drilled and routed all the holes in the CP first.  If you're worried about blowout, just stick another piece of wood underneath the hole as you drill.  I would then clamp your lexan to the CP, trim it to size using a router (I used a dremel) -- and then flip it over and drill the holes in the lexan from the bottom -- that will ensure the holes line up (again, put a piece of wood underneath to help keep the lexan from cracking/moving).  Then add the artwork.

my $.02

[Kitbasher]

To cut the button holes in the lexan I usually build the wooden pannel, drill all its holes and then clamp the lexan down and drill holes in the center of the button hole and insert my router with a flush cutting bit in the hole and route it to match the wood.  Works great.  I also trim up the outside of the lexan the same way.  

[hyiu]

I would not suggest you to drill your artwork....

you can drill your lexan with wood.... or drill wood.. and route lexan.....

but you should finish the wood and lexan... then apply artwork.... and then slowly cut the holes out....

drilling the artwork will most likely scratch it if not torn it....

[Silverwind]

I would not suggest you to drill your artwork....

you can drill your lexan with wood.... or drill wood.. and route lexan.....

but you should finish the wood and lexan... then apply artwork.... and then slowly cut the holes out....

drilling the artwork will most likely scratch it if not torn it....

Right.. cut the art with a sharp razor blade or the likes..
How about drilling lexan if it is by itself?  How about with a scrap underneath it?  Same bit as the wood?

[hyiu]

well.... on the ctrl panels... (sticks..) that I have build....
that's what I do....

I have live size printout of the holes needed to be cut...
(on 8 x 14" paper....)...

then I tape the paper on the wood.... (when I'm doing 2 player... I'll have to adjust 2 papers and align them on the wood...)

after I'm satisfy with the alignment... (and taped it firmly...)

At each hole's center.... I poke a hole.... (so that I know where to put the hole drilling bit....) the hole does not need to go all the way thru.... just enough so that I can notice it when I remove the paper....

after I poke ALL holes... (and re-confirm... and re-double checked...) I take out the paper and start drilling holes on wood alone....

I usually don't drill all the way.... I drill hole until the other side start showing the center hole... then I flip the wood upside down and finish the hole on the other side.... this way.... the edges on both sides are ok.....

at this point... wood is done.....
(of course.... drill all screw holes also...)

now... the buttons are going to hold the lexan and the wood and artwork together in the middle... but to make sure the edges stay together... I usually will have 3-4 screw and nut holding the edges....

now... I align the lexan and wood.... (keep lexan protective sheet intact... ) that means... the lexan is not transparent at this point....

after aligning the lexan... I'll first drill the screw holes around the edges.... (wood hole is already there...) just drilling thru the lexan.... (I use like 4 clamps to secure the alignment at this point...)

then I actually use screws and nuts to secure the lexan to the wood..... and I make sure they align well....

then with the wood facing up (and lexan on bottom).... I use the hole drill bit, and put it in the drilled wood hole... and drill the lexan.....
(see... I'm drilling the lexan by itself.... but the wood does help secures it since the lexan and wood is now secured together by screws and nuts.... I do not have scrap piece below the lexan...

(or other people suggest routing the lexan hole with router and with a proper bit.....) that is a very good idea too...

when its all done... then I remove lexan protective cover... (now its transparent...) and put artwork in the middle and align....

again... secure the 3 things with screws and nuts.... I'll use a exacto knife kinda to poke the screw holes on artwork also....
use a VERY SHARP and thin and narrow knife and slowly cut out each hole....

then put on buttons and joysticks... and wahh laa... its done !!!!

ps:  I used dremel and router to route a bit on the joystick screws positions so that the joystick screw head will sink
into the wood.... (just enough so that the artwork can cover it...) then the final panel will have less screw heads on it.... (I think that makes it looks nicer...)

this is just how I do it... doesn't mean its the best or anything... just want to share....

btw... lexan is VERY good with any wood working tool bits...

so far I'm very pleased.... (even its more expensive...)
I think its worthed....

ps: a pic is worthed 1000 words....
here's a final pic....
http://www.geocities.com/hyiu/pics/Arcade/Cab_and_Stick/a_cp.jpg
(you might need to go to the directory first, and the click on filename to view...)
http://www.geocities.com/hyiu/pics/Arcade/Cab_and_Stick

notice on this panel... there're 3 screws holding the edges....

hope it helps....

[eightbit]

I usually don't drill all the way.... I drill hole until the other side start showing the center hole... then I flip the wood upside down and finish the hole on the other side.... this way.... the edges on both sides are ok.....

If you use a forstner bit and a backer board you can avoid drilling from both sides and still have a clean hole. Of course forstner bits are best used in a drill press so add that to your list of tools to purchase for your project.