Older News
20th February 2004 The three templates are complete and I have drilled the holes in the main MDF box panels (I will leave the top till next week as it is a lot of work). When screwing the box together some of the MDF panels split at the edges even though I had drilled a small pilot hole (with clearance holes on the side panels). I'm also not very happy with the finish of the MDF because of the way the material rips and tears quite easy (even when countersinking the holes), I will have to look for an alternative wood for making the main box (probably leave the main top as MDF though).
Here are all the MDF panels with the holes drilled
All three metal hole templates, the large one is for all the buttons an joystick
Side panels hole template on top of side panel
17th February 2004 The three looms have been made (Joystick, Buttons and Ground) and I've made a metal template for marking out the holes (for the buttons) & Joystick.
11th February 2004 I've made the choice of wire to use (16 strand 0.2mm) and which colour's to use. I was originally just going to use just one colour for the ground (Black) and one colour for the other connections (Red) but this would make fault finding difficult, so I'm now using seven colour's (including the Black ground lead).
8th February 2004 Ordered some more Router cutters for putting on a radius edge instead of a T-Moulding as this should still look professional and not make as much MDF mess. Also ordered a 30mm Forstner Bit for machining the 30mm holes (30mm now instead of 29mm as they don't make a 29mm Forstner Bit), the Flat bit wood drill has some breakout problems with MDF, the Forstner Bit should cure that.
I tried varnishing the top but it did not come out as good as I thought it should, I may just use clear lacquer next just to see how that works out.
Next week I will be making a metal hole template for the eleven 30mm holes as the plastic one has some holes on the wrong place and a metal one would last longer also.
7th February 2004 Tried out the new router bits this morning on piece of scrap MDF and they cut very well, I will be trying it on the actual arcade top this afternoon.
Joystick recess was quite good
Up close Joystick recess
10mm Radius cut quite nicely, this would have been impossible without the template
6th February 2004 Steve at work helped me (as he has many times before) by making a template for the top of the controller out of 6mm plastic. This weekend I should be able to start routing out the joystick recess and the four radius corners of the top section (only if the routing bit and flat drill bits turn up that is).
1st February 2004 The holesaw was not so good at drilling the 29mm holes for the Buttons as the teeth quickly clog up and you have to keep cleaning the teeth, you also get a poor cut hole.
I had a 20mm flatbit wood drill and that was much better so I have ordered some 29mm ones online (most places only sell 25mm then 32mm but no 29mm).
Well I've got my first Router and I must say it's actually a lot easier than I thought it would be, this will make recessing the Joysticks and cutting the T-Moulding much easier. I will be making a cutting guide so I can cut some rounded corners on the main section.
31st January 2004 I'm getting used to TurboCAD LE now so the main layout coming along very nicely, I even modeled the Joystick and a Button so I could get the correct dimensions for the wood, this was much easier and quicker than the method I used before which was a cardboard model and a 300mm rule.
The Screwfix order turned up today but was missing the 6mm Coach Bolts (used to hold the joystick in place), I have email them for a replacement.
30th January 2004 The Joystick and lots of Buttons turned up today, I'm quite happy with the 8-Way Happ Ultimate Joystick I ordered. I also have the top panel ready to be machined. Screwfix items have been order and should turn up to tomorrow. Button layout more or less finished in TurboCAD, now I just have to sort out the height of the box (depends where the buttons and Joystick go).
26th January 2004 Designing the button layout in TurboCAD LE v4.1, you can download and use it for free non commercial use, well worth it as it's a very good CAD package, I've used Autocad and IDEAS but the latest versions of these programs are quite complex to use and centre more on 3D work.
25th January 2004 I've decided to use 18mm MDF in the construction of the main box because the wood (if you can call it that) is strong and of consistent quality. Ordered the buttons and joystick yesterday, they should be with me by midweek.
I will be making a prototype lid out of MDF with all the holes on the next week or so (I already have a cardboard prototype), then I can work out the size of the box that goes underneath.
23rd January 2004 Materials planning and manufacturing methods researched, choice of either metal or wood for the main box construction. Steering wheel is on order (I pick it up tomorrow morning).
20th January 2004 Site opened and domain name registered.
