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O'Boyle's Arcade - by the "book"

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Dmod:
Don't use a router for that, it will take many passes to get through the MDF.

Here's how I cut my trackball hole:

1) Print out the template for the trackball cutting area.
2) Using repositional spray adhesive (available at Lowes), align and stick the template down to your control panel.

Example:



3) Drill starter holes near the corners of the template.
4) Insert the jigsaw into the starter hole and cut out along the template outline.
5) Peel off the remainder of the paper stuck to the control panel.

You may be able to forego the starter holes since you already have the track ball hole there to start from.

I actually routed my trackball plate after I cut the hole but it shouldn't make any difference.

nukedawg:
very nice

Spyridon:
Spent some time working on the trackball tonight.  I printed out my template for the 3" Happ trackball, but I couldn't get it to line up perfectly.  Since I already had the trackball area clearly marked out, I decided to just place the trackball on the control panel top in the correct spot and trace around the outline.

This gave me a good idea on where to cut out.  I then pencilled in the area I would be cutting out

Full control panel shot

Next step was to drill some holes to allow my jigsaw easy access.  I could have just started from the hole I cut for the trackball, but it was easier going from each corner.


Time to cut...


Almost there...

Spyridon:
And the completed cut


After a test fit to make sure the trackball fit (it did), I drilled the holes for the mounting plate.

A nice flush fitting trackball plate:



Spyridon:
Next step was to start working on the joysticks.  I printed out my template, but again it was slightly off.  I decided that it would be easier to just trace the outline of the joystick.  To do this, I needed to take the joystick apart.  That E clip scared me!  Luckily, it didn't go flying across the room and the joystick was in pieces...


To trace out the outline, I turned the base of the stick upside down and lined up the center with the hole that I had already drilled out. 


I then traced out the outline, including the holes for the screws


Repeat for the right side


Next I drilled some small pilot holes.  Once the router hits it, I would lose those marking.  This way I can still line everything up


And that's as far as I was able to get tonight.  Back on it tomorrow morning.  Hopefully, I can get all three joysticks done.  After that is the fun part of putting everything together.

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