I haven't had much time lately. After a recent trip to LA for business, I have been taking time to clean up around the house and plan for my Super Bowl party this Sunday. In light of my latest setbacks, I am starting to think that it's likely that I won't have this stick done for another week or two.
Things were looking up initially, I made the four side pieces with miter cuts. And the console board with a jigsaw, thought I'll probably make the next one with a circular saw.
After getting all four sides of the housing cut, I gave practically coated each angle in glue stuck the four sides together and put them in a vice for an hour. I stuck two larger pieces of wood on the outside of outside of the housing to evenly distribute the pressure of the vice.
Next I started to get the button/joystick layout on the console board. This took a little research, I went to a couple of arcades about two months back or so and eyed the spacing between buttons. The standard spacing between buttons at an arcade is pretty wide I'd say about 3/4". I on the other hand like the buttons closer, so the below configuration has them spaced at about a 1/2" between the buttons.
Here's were things got really hairy. During drilling the holes for the buttons I noticed that the spacing between holes were getting a little nicked when starting the adjacent hole. Moreover I wasn't paying close enough attention to the housing that had dried with two of the four corners at a less than perfect mesh. After an a initial appraisal of my errs...I went a little apeshit!
I spent nearly two hours trying to realign the housing, and at one time went as far as trying to fasten the corners with screws, but the damage had been done. The buildup of glue and my later attempts to sand it off had made imperfect cuts by an imperfect craftsman so fucked that I was only left to start cutting new pieces for a new housing. Then adding insult to injury, when I tried to drill the last four holes a huge nick came out of the wood - I am Jack's wasted life.
I have started a new board and housing though I am going to use a circular saw to cut the board and I have increased the spacing between the buttons to reduce damage done to the board. This time around the housing will be regular straight cuts and will be fastened with carpenter nails. I expect to be done with the board and housing sometime next week.
