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Metal CP - Rebuild and Redrill/punch?
Namco:
My CP was like swiss cheese when I took the CPO off of it. What I did was I got a piece of sheet metal and cut it in the shape of the old CP and drill the holes through that. Drilling through 1/16th inch (1.6mm?) was no problem with a hole saw, especially if you drill a little pilot hole first. The only problem is filling the areas where the old button holes were. I used wood putty and sanded it flat, but I should have used bondo looking back on it.
Working with sheet metal is easier than you think. The metal saws are just a few dollars and the metal holds up very well. Very forgiving material to work with.
Necro:
I guess my question leading off of this is how do you drill the original CP (with the misplaced holes) before repairing it? Throwing the other piece of metal on it makes sense, but would the material shift/move when using the punch or saw? (I'm thinking it bends/shards when you try to cut it like this).
Either way, it seems that picking up a crappy used CP is my best way to go in my Omega Race retrofit since the CP holds two bezels in place.
Namco:
First you use a paper template to drill your button holes on the blank metal. Around the perimiter of the CP there were bolts that hold the plexi on. Just clamp your blank onto the CP to drill out those holes, then bolt it on. Use the blank CP with the button holes as a template to drill out the old CP. Once you're done, bolt it to the back of the old CP, glue it down with some industrial strength glue, and fill the top flush with bondo. Clean up the holes with sandpaper or the hole saw, then primer the whole thing viola', good as new.
this might not apply to your case, post a pic if you can.
cmoses:
--- Quote from: Namco on October 21, 2008, 01:31:24 pm ---First you use a paper template to drill your button holes on the blank metal. Around the perimiter of the CP there were bolts that hold the plexi on. Just clamp your blank onto the CP to drill out those holes, then bolt it on. Use the blank CP with the button holes as a template to drill out the old CP. Once you're done, bolt it to the back of the old CP, glue it down with some industrial strength glue, and fill the top flush with bondo. Clean up the holes with sandpaper or the hole saw, then primer the whole thing viola', good as new.
this might not apply to your case, post a pic if you can.
--- End quote ---
Can you clarify the following directions
1. Cut out sheet metal in same shape as control panel
2. Use paper template to mark and cut holes in sheet metal
3. Use sheet metal template to cut holes in original control panel
4. Glue sheet metal template to bottom of control panel
5. Bondo the top of the control panel filling in all the holes
6. Once bondo is set, then redrill only the holes that you are using
Any "in progress" pictures that you can provide would be helpful.
Necro:
I get the theory here, I guess what I'm not getting is how in the heck you get the circle saw to work right if say....you have to cut a circle where half it the circle is already gone - including where the center of the hole drill would go. Make sense? Basically, new hole overlaps an already existing hole. (So basically step 3 below).
And you can drill bondo with a spade bit without it obliterating/shattering itself?