List of hardware needed for control panel

[iAtoria]

What is the minimum hardware requirements to make a CP like this t-molding will be added to it as well:

http://members.shaw.ca/knievelgod/woody/cpt.jpg

[thatitalian]

Ahh, the Knievel special!

Well you will need:

Router (tool), probably the greatest invention ever made, with the following cutters:

Flush trim bit (cutter), this is used to make flat, smooth sides.
Slot cutter (cutter - for t-molding), generally you would need a 1/16" cutter for 3/4" t-molding.
Pattern (template) bit  (cutter), this is used to make the recess.

Drill (tool), with the flowwing bits:

Forstner bit (drill bit), for making button holes, you should use a 1 1/18" (28mm) size bit if your buttons are standard push button size.
Drill bit set (drill bit), generally a set is good to have in order to drill holes for screws for the joysticks and also for the trackball mounting plate, amongst other things.

Jigsaw (tool), to cut out the general shape of the CP.

And finally, a ruler! Remember: measure twice, cut once!

[drventure]

Be sure to use a scrap piece under the CP when you drill out button holes, so you don't get a lot of tearout

[Chadwick]

Get at least 4 good clamps...  You can never have enough clamps.

[iAtoria]

Thank you guys, looks like I need to go out for a router and bits, or borrow it from someone.  I have the other pieces of hardware.  Very helpful

[drventure]

Depending on where you are, I've found craigslist to be a VERY good source for getting tools for cheap.

Seems that there's always someone looking to ditch tools for one reason or another.

[iAtoria]

I am still a bit of a woodworking newb, so I checked craigslist out and found a couple routers, but there are two different kinds (plunge and regular).  Which is the one I need?  Could you recommend any models that are preferable?  Also, do I need a router table or can i do it by putting the wood on two stands?

[thatitalian]

Well plunge means just that, you can plunge it. Fixed router is just  a fixed base position.

I would go for the plunge simply because it can be "fixed" anyway, at least that is what I have.

You don't need a router table, you will need a "table" though or workbench to clamp the wood down. It needs to be rigid so it doesn't move and you can concentrate on the router flying out of your hand.

[Octo]

Definitely go with the plunge router. So very versatile and much more stable on those inner cuts (you don't have to tip it in). An important note is to not let the router sit in the MDF for too long, or it will heat up and leave scorch marks. Just make steady passes and don't take off too much at once and you'll be ok. Get a couple bar clamps, super cheap at Harbor Freight, and a good straight-edge or T square.

[drventure]

A long piece of angle iron works pretty good for a router guide as well, if you've got one laying around.