Retry - Working On Pre-Laminated Control Panel

[dislecksea]

Well, let me start out by apologizing for my previous post.  I had a nice long detailed description of what I was doing and what my question was and I thought I posted it correctly.  However, when I came back to check for responses, it was just the word “OK”.  Again, sorry about that.

Let me try again.  Basically, I purchased a pre-built cabinet made out of 3/4 inch plywood.  It was already laminated when I got it (project announcement - http://forum.arcadecontrols.com/index.php?topic=58472.0).  I am now getting ready to install my buttons, joysticks, trackball, etc.  Like many here, I am not very experienced at woodworking (I took my “from scratch” cabinet apart because it was so ugly).  I have done my homework by searching on the forums, but I wanted to see if anyone here had any additional suggestions or could confirm that I am probably doing this the best way possible.

For the buttons and joysticks on my last build, I used various sized hole saws to cut through non-laminated MDF.  Based upon my research, it appears that I should 1. measure where I want to cut, 2. drill a small pilot hole through the CP from the top, 3. tightly clamp another piece of wood to the top of my CP, thereby sandwiching the laminate between two boards, 4. flip the CP over, 5. use the pilot holes to guide my hole saw, and 6. go at a high rate of speed and low pressure to cut through.

Did I miss anything?  Is there a particular type of board I should clamp on top of the CP?  Any other suggestions?

What about for the trackball and spinner, where I may need to cut a square hole?  On the MDF build I used a jigsaw that I borrowed.  Any guidance on how to best cut a square on plywood with laminate?  I don’t have a router (but could buy/rent one if I new how to use it) but I do have a dremel tool, if that would help.  I do have a mounting plate for my trackball (don’t know if they make them for spinners) so I guess the cuts don’t have to be perfect.  However, I do want to do this as well as my meager skills will allow.  Any guidance from those with more experience would be appreciated.

Thanks!

[Dudeman]

??

[dislecksea]

Per my initial post - I checked and the post now looks correct.  Again, sorry about that.

[GoPodular.com]

Is it laminate or is it melamine?

Laminate should be drilled top->down it doesn't lift from the mdf.  Melamine *might* be better drilled bottom->up with a scrap board to minimize tearing.

The easiest thing is to use a router for making the recess for the trackball plate.  If you have melamine, you'll be able to square-up the corners fairly easily with a razor.  If you have laminate, you're in for a beating to square up a corner like that.  I'm really not sure how you would do it with the laminate already on.

[dislecksea]

I have sent an e-mail to the guy who sold me the cab asking whether it is laminate or melamine.    I have to admit that I don't know the difference between the two.  Is there any way that I can tell by looking at it?

Thanks for the router suggestion.  I am actually not planning on recessing the trackball plate.  I know that there are lots of folks who recess theirs, but I am afraid that it very well may be beyond my woodworking skills to do so.

Thanks

Miles

[MikeDeuce]

High pressure laminate is usually much thicker, like credit card thickness. Melamine looks more like a paper layer, and is not as strong and cheaper.

Mr Godpodular has a helpful page on his site that will speak more to it:
http://www.gopodular.com/support_articles/melamine_vs_real_laminate_arcade_enclosures.htm

[dislecksea]

It turns out that it is melamene not laminate.  For clarity, it has been applied to plywood, not MDF or particleboard.

So, cutting bottom up is probably better?

[GoPodular.com]

With plywood as the substrate, I'd make a sandwich to do the drilling.

[Layer one = scrap of whatever]
[Layer two = melamine side up]
[Layer three = scrap of whatever]

I'd go top->down through the sandwich.  The top scrap will keep the melamine from tearing, the bottom scrap will keep the bottom  from blowing out (similar to what I said about lifting the laminate above, only it would be the plywood).