Metal Control Panel, question on how to work with it.

[Warborg]

Ok, so I am in the process of converting over a Xenophobe cab, and am thinking of keeping the CP top metal, but don't have a ton of experience working with metal like this (just cutting up pipes with a dremel to make prop Lightsabers...     )...  So, I have a bimetal holesaw that is good for the pushbutton and joystick holes, but as far as cutting a 3" hole for the trackball...  What would be the most effective (cheapest) way of doing it?  I assume I am going to be using galvanized steel for the CP top...

[TOK]

I have a Bally/Midway cab that is different from yours, but I believe it has the same control panel, the one with the sort of triangular metal base that the CP bolts to. My machine actually had wood under the metal top. I separated them, traced the shape of the wood onto MDF and cut both that and a piece of 1/8" plexi to create the shape for the new panel. The new piece can be wood screwed to the existing metal base.

I can get some pics of you want.

EDIT: I took some pics and posted them in your Project Announcement thread.

[Apollo]

In my opinion 2.5 mm electro galv steel is the best metal to use for control panels (easy to work with and powder coats very well). I have cut 3" trackball holes in this kind of steel and have always used a 3" bi-metal hole saw (similar to the saw you have for the buttons just bigger) with excellent results. You'll need good round and flat metal files as well, wear gloves and eye protection. Just remember to take it slowly metal is a lot less forgiving than wood if you balls something up.