Eventually I will do a step by step and write-up.
For now, i'll just be posting a couple pics of the arcade sticks that are inlayed / locked-in to the cabinet. Technically, I only needed one of these, but I like the idea of experimenting with different woods and button/stick color combinations.
The woodwork was done by me, the aluminum control panel, panel overlay, buttons, sticks, pcb's, and ethernet Cat 6 / R-45 jacks connectors were all purchased at various places.
Sticks are Seimitsu LS-32's, buttons are Sanwa 30mm / 24mm screw-ins.
PCB's are McC's. Connection is via ethernet Cat 6 cable leading to a R-45 jack. Sticks are compatible with all of my consoles except PS3 and N64. I currently have cables for SNES, NES, SAT, DC, GCN, PS1 and 2.
EDIT: Here is the cab, in the house as of today, 6/17/12:
To note, the monitor is inlaid into the bezel - the bezel is TATEable for JAMMA vert games, by simply sliding the bezel out of the rails, 1/4 rotation, drop back in.
Both control panels obviously fit into the cab - I'm using the Red Oak one for now. The Mahogany looks a bit better and can serve as a stand alone stick upstairs or elsewhere, etc. But it is great to have a backup!
I used a semi-gloss poly (5 coats, sanding between...). It is great - no tack, no fingerprints, yet very smooth on the wrists / arms.
Here are the sticks:
Problems so far?:
1) I completely spaced attaching the panels into the wood stock (it inlays into the 3/8" birch plywood and rests on some scrap stock, positioned at the (6) screw holes). So...I used a generic screw on each of them and don't like them at all. I need to pick of something that will sit more flush and be more aesthetically pleasing.
2) There are some small gaps between the panel and the birch overlay - I anticipated this and have some matching caulk that I can fill-in from underneath. I used a jigsaw to cut out the panel inlays, and while it was very close, there are some very slight variances that I wish were better - you can see them in the last 2 pics.
Very nice! A Well thought design with the connecters. Have you gutted any console controllers PCBs yet? Maybe hit the PS1 first, then try adapters? This will save on having to custom build some of the extra PCBs.