yeah, just like the lexan. once you have a template it's pretty easy after that just rough cut the next piece a little bigger than copy with the flush trim bit. done and done!
those small buggers are the exception I didn't think of a lexan cover, humm...
-time passes-
OK, this may be easier than I though. I think I'd drill a .52 hole in the lexan and drill the 1" hole all the way through the MDF and just tighten the button down to the lexan, so the button will actually only be connected to the lexan (this way will also definitely make sure you have enough room underneath)
or you could cut out the diameter of the button face and have it sit below the lexan, but I don't think that would look as nice
the foam bit on mine were black and snugged up against the bottom of the back lip of the button face above where the threads end, it's a bit hard to see but it gives you another 1/16"ish space available to clamp down
That makes perfect sense! I'll go ahead and do it how you original suggested doing it for the prototypes since I won't have the Lexan at hand.
Here's a new version of the layout. Starting to try to figure out where to put admin buttons, coin buttons, start buttons:

The buttons at the top are actually the tiny circles. . the other circles are there to know where to cut the bigger holes on the underside. The buttons are, from left to right:
exit coin1 start1 pause ffwd coin2 start2
I'm pretty sure ffwd could go away and just have a pause there. I could probably do this instead:
coin1 start1 pause exit coin2 start2
since the buttons are hard to push and not have the button at the left. I don't know if visitors are ever going to use ffwd, if not, then I can use a shifted combo for that. Heck, I might even be able to get away with visitors never pausing. Do others find that visitors want to pause?
Also note that it is actually a couple inches taller than this. . I haven't represented that in the drawing yet. I have to still figure out how much taller. The current prototype that I'm working on is really darn tall so that I can cut it down until it is right.
So are the U360 shift modes really messed up, or is it just me? Seems like you always get the shift button to register its own keypress along with the other button that you hit. This is different than the IPAC, which is kind of a bummer. I'm not likely to use the U360 for shifting if this is the case. I'll just do all shifting off of the little buttons at the top and have them all go throug the IPAC.