Install Help - Plexi/Lexan Control Panel Surface

[whynotpizza]

Hi again,

Been searching the boards (and must be missing something) ... I and cannot find any decent info on install techniques from folks who have installed plexi or lexan on their control panel top surface.

How to route edges?
How to cut the holes?
How to try not to break the plexi or lexan?
What tools work best?
Pictures of the install?
How to counter-sink screw holes?
How many screw holes to use?
....

Does anyone have a link or know where to get some good data (which is still current - i.e. no broken links)?

Any tips would be appreciated, as I plan to try this over the weekend,

Thanks,

  David

[ChicagoDave]

How to route edges?

==>  By "route the edges", I assume you mean the lexan.  I used a lexan cutting tool.  You simple score the lexan several times and then crack off the edges.  Many others have used a router and a laminate flush trim bit.

How to cut the holes?

==>  I used a 1 1/8" forstner bit.  I used the sandwich method by placing the control panel, the lexan, and then a piece of scrap wood.  I used the control panel as template for cutting the lexan.

How to try not to break the plexi or lexan?

==> Used the sandwich method mentioned above.

What tools work best?

==>  See above.

Pictures of the install?

http://www.davestojak.com  and look at the control panel link.

How to counter-sink screw holes?

==> I used a counter sink drill bit, and wood filler to cover the screws.

How many screw holes to use?

==> ?

I suggest getting Saint's book, "Project Arcade".  It will answer all of your questions and was a big help...

[AtomSmasher]

First off, the wiki has good info:  http://wiki.arcadecontrols.com/wiki/Plastics

IMO using a router and a flush trim bit is the only way to go when cutting plexi/lexan.  Its fast, easy, and extremely hard to screw up and break the plexi/lexan.  Just use the wood part of your CP as a guide for the router bit, it also guarantees that the plexi/lexan is a perfect fit.

To cut the holes, I used a drill bit just big enough to fit the flush trim bit through, then just used the router to cut the holes.  The main thing to remember when drilling holes is to put the drill in reverse, you actually want to melt through the plastic, not cut through it.

I didn't use any screws to secure it because every button acts like a screw and holds it down.  since the edges of the plexi/lexan is up against t-molding, it doesn't pop up or cause any problems (at least it never has for me).

pics:
just after cutting the sides:


buttons now cut out:


finished:

[whynotpizza]

Hey guys,

Thanks for the posts and additional info.

Lexan was bought Saturday night, and yesterday most of the afternoon and evening was spent working the cuts.

I am amazed at how easy this was, although it took a boat-load of time to finish as I was really careful when making the cuts - 1 messup and the whole piece would have been wasted!

A must is to get a test piece of lexan and use various cuts. This is the only way to see how to set depth on the router, and work with different bits.

Tools I used: Hand-drill, Router, Clamps and Bricks to hold stuff down
Bits for the router: two types (a) 1/2" V-Groove bit for the corner counter-sink holes and (b) 1/8" Roundover bit for the straight cut edges
Bit for drill: (a) 1 1/8" Forstner Bit for hole cutes - this is a must and worked great

Here are some pics of my success.

 

   David

[Lutus]

Sweet mother, do you have a pic of the cabinet you are putting that control panel on?

That puppy is big!


Not saying that is bad but just wondering why so big since some of the things are spread apart quite a bit.  Ok, stepping off of the soap box.

[whynotpizza]

Yes, this is big.

Turns out I purchased a Mechanized Attack 4 cabinet on ebay last month, and have been working feaverishly to gut it and ready it for the control panel I am also building. I hope I didn't offend anyone in the Mechanized Attack camp, since I cut into the side art to build my own personal system. (hee hee). The frame on this unit is 3/4" MDF and was in very good shape, so it has been very nice to work with. It also came with a working Coin Door, Marquee and solid glass front. Not bad for $62 with local pickup/no shipping!

Anyway, overall control panel top surface is 44" wide x 16" deep. It has a player 1 station (4-way sticks) and a player 2 station (8-way sticks) and also has a 3" HAPP trackball in the center, along with a HAPP 8-way Heavy Duty flight stick. And the spinner (of course) is an Apache Controls Blackhawk Push/Pull. That spinner rocks for all sorts of games! Oh yea, I also have 2 ACT LABS (original style) Light Guns.

Anyway, the control panel box also has a solid pull-out shelf unit in the front, for access to the KB/Mouse. I am glad I spent the time to make the shelf, it will come in handy over time.

Here are some pictures.

    David

[Lutus]

That would explain the size!!!   

I don't think you will be crucified for Mame-ing that cabinet.  But just wondering, did that thing work when you got it or was it sold "non-working"?

[whynotpizza]

The original cab was sold as is, and it appeared to turn ON but beyond that, nothing really happened on the monitor and it seemed to need help, which I could not provide. So instead, I ripped the guts out and got to work.

[Lutus]

Are you going to keep the guns that came with the cab?  I personally don't want them but you could sell or give them away in the "Buy/Sell/Trade" forum.  Just a thought.

[whynotpizza]

Good minds think alike. 

Just sold the guns last night...
  http://cgi.ebay.com/ws/eBayISAPI.dll?ViewItem&ih=013&item=230025306331

[erictrumpet]

That's a nice looking project, pizza. I like how you selected colors for the control panel paint and CP overlay that compliment the sideart! You might want to start a thread in the Project Announcements board to keep us informed as this beast comes to life. You certainly picked premium controls: Happ 8-way flight stick, Happ 3" tb, Apache push/pull spinner (I have one of those too), and TWO act-labs guns. You will have one heck of a DOT setup there with the Blackhawk and the Happ heavy duty flight stick! I love those Happ sticks, they are awesome. Good luck on your project...

P.S. Atomsmasher, I love your Galaga-themed CP.

Eric.