The straight bit is what I will be using for the areas that I plan to counter sink. This way, we can move the router along a template of jig, and replicate the cut exactly. The flush cut bit has a bearing on it that is exactly as long as the cutting edge. I will be using 2 bits, the flush cut or flush trim bit and a straight bit. I don't own a router, so I borrowed one from a friend. The reason I need the cutout in the shape of the trackball housing is because I want to countersink it so that the trackball sticks up farther from the top of the control panel. The trackball will come out of the top of the control panel via a 3 1/2" circular hole. The large irregular shape in the center is the cutout for the trackball. The top center button is for a spinner, which will be added at a later date. I also added a 7th button for both players "Neo Geo" style. I will also be wiring the coin refund switches to add credits in MAME when pressed. I have added buttons next to player 1 and player 2 for player 1 and 2 coins/credits, since this machine will have MAME on it. You have to be careful and go a little slower than you are used to, but you will get VERY clean cuts. Forstner bits don't just use jagged teeth to cut into the material, they have scrapers that cleanly bore out all of the material. By the way, 1 1/8" is the standard button and joystick hole size for all of the parts I bought. That is not what I want, I want clean so I purchased a 1 1/8" Forstner Bit for about $10.
You CAN use a hole saw for this, but they aren't really designed to make clean holes, they are designed to make a hole and who cares if the edges look sloppy. Once I re-measured and made sure I was happy with my markings, I got ready to drill.
I clamped the baseline template to my blank template and traced the lines for the trackball recess, player 1 and 2 start buttons, and the joystick hole locations. Why create a template? You really don't have to, I just wanted to since it's relatively easy and if I wanted to duplicate the control panel for any reason, I don't have to disassemble my populated CP to do it. One piece cabinet grade Maple plywood which will become the final control panel, and another, cheaper piece of 1/2" regular plywood which I will use to create the template. I started by cutting 2 pieces of 3/4" material to the exact size of the control panel. I used it as a baseline to create my control panel. This template was generously sent to me by jp335i on Klov.
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