How to make own mounting plates?

[RayB]

I'd like some advice on creating my own simple mounting plates for a couple buttons. I don't have a big arsenal of tools. Here's the deal:

My control panel is wood, about 1" thick. I have drilled holes for the buttons and joysticks. No problem there. But my two admin buttons will be small Radio Scrap buttons (needs half inch hole) and the player start buttons will be Atari volcano buttons.

Both those kinds of buttons are really meant for mounting to metal CPs. The Atari ones are particularly difficult since they have a rectangular base part, and use a round hole, need to be sticking out alot so the cone can be screw on.

I could route out hold underneath but I'd need to leave about 1/8" of wood to mount the Atari buttons properly. That's really thin for partical wood and it'll probably just crumble on me as I route out the hole.

The best solution would be to route out a thin area on top, cut a large piece out, then lay a metal mounting plate with the button hole cut out of it. (Like people do for trackballs.) The risks here is I have to route out this area with alot of precision so as not to have gaps between the plate and wood. How do people do it? What bit do I need? I have a router but the bit is a big rounded one. It only cuts holes with rounded edges.

How do I make my own mounting plate? Is there an easy way considering I don't have much in the way of fancy tools? (I have the basics: A drill, a sabre saw, hammer, pliers, screwdriver, small Dremel, basic hand router, and that's about it.)

[markrvp]

The best solution would be to route out a thin area on top, cut a large piece out, then lay a metal mounting plate with the button hole cut out of it. (Like people do for trackballs.) The risks here is I have to route out this area with alot of precision so as not to have gaps between the plate and wood. How do people do it? What bit do I need? I have a router but the bit is a big rounded one. It only cuts holes with rounded edges.

You can use that bit to recess everything but the corners and then use a chisel to square out the corners.

How do I make my own mounting plate? Is there an easy way considering I don't have much in the way of fancy tools? (I have the basics: A drill, a sabre saw, hammer, pliers, screwdriver, small Dremel, basic hand router, and that's about it.)

Honestly, the best solution is to have a metal shop make you one.

[Wade]

Go buy a small plate from Lowes which is close to the size you need, then just make your hole THAT size.  Rather than do the hole first and then try to cut a plate.

I have found various plates in Lowe's meant for different things, usually for a dollar or two.  Usually they are brackets or plates meant for joining studs or joists.

Wade

[Witchboard]

Are you going to be using lexan over your CPO, if you have one?  You could just drill holes big enough to house the button base and drill the holes to fit in your lexan and mount them to that.  The nuts being under your CPO of course.

[RayB]

Are you going to be using lexan over your CPO, if you have one?

No, nothing on top but printed overlay.

Go buy a small plate from Lowes which is close to the size you need, then just make your hole THAT size.

[rdagger]

You could also make a small mounting plate out of Lexan and just route it flush with your CP.

[RayB]

You could also make a small mounting plate out of Lexan and just route it flush with your CP.

Too flexible, no? Buttons get pushed on. Sometimes really hard (I wouldn't, but you never know with kids).

[CrustyPresident]

I don't know what shape you want the mounting plates to be, but if you want something easy you could us a large stainless steel flat washer as the plate. You could then use a forstner bit to cut the recess. This would require each button to have it's own plate but would be less work.

-Scott

[markrvp]

I don't know what shape you want the mounting plates to be, but if you want something easy you could us a large stainless steel flat washer as the plate. You could then use a forstner bit to cut the recess. This would require each button to have it's own plate but would be less work.

-Scott

That's a very good idea.  Way to go!

[RayB]

I don't know what shape you want the mounting plates to be, but if you want something easy you could us a large stainless steel flat washer as the plate. You could then use a forstner bit to cut the recess. This would require each button to have it's own plate but would be less work.

-Scott

I'm gonna have to look up what a "forstner" bit is.
 

Here it is: http://www.wisegeek.com/what-is-a-forstner-bit.htm

[JonnyBoy]

Yeah, I used a big 3 inch forstner bit to drill my fan holes. They're nice and cut well, but are near impossible to sharpen once they dull, not to mention expensive.

[DrewKaree]

Yeah, I used a big 3 inch forstner bit to drill my fan holes. They're nice and cut well, but are near impossible to sharpen once they dull, not to mention expensive.

Take them to a woodworking shop or to someone who sharpens saw blades.  They're actually rather easy to sharpen if you have the right tools or a jig to do so.  What part are you speaking of when you refer to sharpening?  I've done several because it's expensive for the shop to do 'em, and never thought it was hard, not even the first time I did it

For cheap versions, see

www.grizzly.com 
www.harborfreight.com

For what you'll use 'em for, they've got the price you need.  Also, woodsmith seemed to have pretty decent prices (for a forstner bit, that is) for their low-end forstners.  I picked up a 3" for $16 to make some cupholders in a project I had.

[JustMichael]

RayB, which Radio Shack buttons?  I am using #275-1547 for admin buttons and I drilled the correct size hole partway in from the top to make a hole the button sits in.  I then drilled a smaller hole from the bottom to let the wires out but not big enough to let the button go through.

[RayB]

RayB, which Radio Shack buttons?

[JonnyBoy]

I was just going buy what some guy at work told me about them. He said after the first time you sharpen them they get harder and harder to sharpen well. I guess that's what I get for listening to a know-it-all egomaniac from work.

[RayB]

OK so I ended up using a short hole saw to cut out a portion of wood underneath, chiselled out most of the wood, and then used my big router to even it all out to the correct depth, using the edges cut by the hole-saw as the guide. Worked out pretty well. Though I then discovered I had cut down way too deep.    More on this posting in my Project thread...

[Wade]

I like those buttons too, and will probably use them on my MsPac cocktail, since I don't have the real buttons and don't want to spend $12 each from twobits.com.

The big recessed washer idea seems like a pretty good one too.

Wade

[ahofle]

Ray, did you ever get this worked out?  What would you suggest now that you've tried it?  The washer method?  I may be getting a couple volcano buttons soon and was just wondering about mounting them on a wood CP too. 

(I love the search button)

[RayB]

Oh, the method I posted last is what is still "standing" so to speak.
I would not recommend it for mounting anything larger than a button. I think a large area done this way (like for a trackball or joystick) would be too weak.

[Havok]

RayB, which Radio Shack buttons?  I am using #275-1547 for admin buttons and I drilled the correct size hole partway in from the top to make a hole the button sits in.  I then drilled a smaller hole from the bottom to let the wires out but not big enough to let the button go through.

I prefer these, they almost look like miniature arcade buttons, except they are convex rather than concave.

Hey - that's the same button I used for my power, except red. One button turns on the cab, with a bits ltd power strip...

[PCtech]

I was just going buy what some guy at work told me about them. He said after the first time you sharpen them they get harder and harder to sharpen well. I guess that's what I get for listening to a know-it-all egomaniac from work.

You work with DREW?!   

[DrewKaree]

Conflicting evidence yer honah.  First, I told him they're hard to sharpen, and then I told him they're not? 

Move to strike PC Tech.

No no yer honah, not his testimony, HIM.  POW!  To da moon, Alice!