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Control Panel II Scott decided on the
following items for his control panel: two Happ 8-way Competition
joysticks, a J-stick balltop joystick, a
GoovyGameGear
Tubospinner,
To be finished soon!
Template for routing for joystick I always route out underneath
the control panel for each of my joysticks. This gives them
additional height. For the first time I constructed a template to
make my life a little easier. If you don't feel a need to build
this template, feel free to skip down to the next section on
layout. I
provided this instruction for any interested parties.
Below is a diagram of how I arrived at the interior template
measurements.
 
Basically what the diagram shows is that I measured from the outside
edge of the 1/2" straight bit that is in the router to the edge of the
router base plate. A picture of this measurement is to the right.
The template will be for the router base to bump into and ride along, so
the cut ends up being perfect.
I took a piece of 3/16" masonite (hardboard) and cut a 14" square piece
from it (see A). In the middle of the resultant board, I created a
square with the measurements from the above diagram (8-3/4" x 9-1/4"),
and drew it with a Sharpie (see B). Next, I cut the square out with my
trusty jigsaw, after first drilling two holes in the middle (C) for the
jigsaw blade to get through initially. Next, I cleaned up the hole
with a bit of sandpaper. Now I had the template built and ready to
use a little later.
Layout You can now take the control panel
top blank you cut previously and layout your controls on it. I'd
recommend first taking the base and lay it atop the panel, just like it
would be placed when attached. Then draw a line around the box.
Remove the box, then draw a box within that box, in one inch.
What this will do is give you an area that is no-man's land- nothing can
be placed where it would touch this line.
The PDF document that I use for the various Happ templates is this
trusty one you might
recognize from my original control panel
page. I do a Select... on each image I need, then print them
each out, keeping 100% scale. I then cut these items out with
scissors, and tape them to the panel blank. Play around with the
layout until you are happy, then take each item down well with a couple
pieces of tape.
My strategy is to take a drill loaded with my 1-1/8" spade bit and
slowly start each button hole. Get it centered exactly right, and
drill down just enough so you'll easily be able to find the hole when
you remove the paper. Do the same with the center of each joystick
hole. Finally, take a ___" bit in the drill and start to drill a
hole in each corner of the joystick mounts. So the same with the
four trackball bolt holes. After you've done that, you can remove
the paper pieces and finish drilling through each bolt hole.
What I've found works best for me is to next figure out the outline of
the trackball itself.... You should have been provided...
Drill a few 3/8" holes along the edge of the line you drew (see E). These
will provide you a way of getting the jigsaw blade through. Then
carefully use the jigsaw to follow your line as closely as possible (F).
You should end up with a hole shaped something like G shows.
Note- Although this hole's shape appears goofy, it fits both the Betson
and the Happ trackballs perfectly.
For each button hole, drill
through most of the way from the front, until the center pops through
the backside. Then flip the panel and drill from the backside
until you are mostly through. Finally, flip it back good-side up
and finish drilling through for all the button holes. This sounds
complicated but is obvious once you begin. H through J shows the
process.
  
   
   
   
   

To be finished soon!

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