Star Castle Cpos-The Finishing Touch

Where alot reproduction pieces end this one just begins...From ScreenPrint to Fabrication

I think Ive covered the printing process in so many other posts, this is color 1, this is color 2...etc.
So I thought Id spend a little more time explaining the fab and finish.
This Cpo was originally silkscreened printed on the reverse side of 1/8" plex, like a Donkey Kong.
Which poses a different problem for completing this. Where typical Cpos of metal or polycarbonate can be punch with dies, Plex can only be fabricated 1 of 2 ways routing or laser cut. Which is how Arcade Renovations did the DK cpos years back. Well since I dont have access to a laser and wanted to keep the price on this small run down I went with the router route. Besides Cinematronics didnt have a laser cutter back in 1980 either.

Brian over at Game Stencils.com laser cut me a jig in 1/4" acrylic from a vector file I drew outlining the original control panel
and it was a PERFECT match. BTW nice touch on the etching adding my logo and job name.

With the Cpos all pre-masked stops are set in place and some pilot holes are added for the to the cpos on the drill press.

Then the jig is set in place with some double sided tape to keep it from slipping though adding vacum tape and threading the jig fitting it with a air valve so it could be hooked up to a vacum pump is probably more common.
so with everything in place each panel is routed down with a flush trim bit to the same size and shape button holes and all.

Well 1 down 49 to go...the mounting holes are also then drill out on the press and voila you've got yourself a reproduction like no other. Now available at ThisOldGame.com for a limited time.