Had some friends over to play tonight. So far the only negative feedback is the player 2 thumb button getting in the way when playing Robotron (or any game that uses the right stick. . I prefer Pac-Man this way). I'm not quite sure what to do about it yet. Here are things that I know can change:
1) The left stick can move at most an inch to the left (probably less) without the player 1 joystick hand hitting the side of the cabinet.
2) I can't move the player 1 buttons closer to the player 1 stick unless I want it to not be exactly the same layout as player 2, where the buttons need to move furthur from the sticks
3) I don't think the player 2 stick can move left at all without player 2's hand hitting player 1's buttons.
4) Player 2's buttons are as far right as they can physically go given cabinet constraints.
These are the options I can think of so far:
1) Get rid of the thumb buttons and go with a 6-button per player layout.
2) Move the thumb buttons to the right a bit
3) Move the player 1 stick an inch (at most) to the left which would give a 1/2 more space between the joysticks and buttons for each player. This might actually be enough to fix the problem. I may have to cardboard/paper that to see how it works. If that isn't enough, I could also move the thumb buttons to the right a fraction of an inch.
Here's the most recent layout:
