PHOTO

This project differs from my first project in the following ways:

Part of a team of three people
Built 4 cabinets simultaneously
Used an Xbox instead of a PC
More modern design than the Pac-Man style cabinet
Used a 25" TV instead of a computer monitor

Phase 1 — Cabinet Design Planning

System CPU Strategy

Approach: Xbox — to run off-the-shelf arcade emulation software like Namco Museum 50th Anniversary, Midway Classics 1/2/3, Capcom Classics, Taito Legends, and pinball emulators like Pure Pinball and Pinball Hall of Fame.

Advantages: The Xbox is much cheaper than a PC with similar computing power. Pelican 'Real Arcade' joysticks (~$50 each) use the same high-end arcade joystick and button switches as professional parts suppliers. Bonus: Xbox Jukebox software and other Xbox games (Burnout 3 — highly recommended!).

Joystick Strategy

Not bad for ~$50! These sticks use real arcade machine parts. The universal variety connects to GameCube, PlayStation 2, and Xbox — and I extended the cabinet with all three consoles. Buttons and joysticks can be repaired using standard arcade cabinet repair parts.

Cabinet Design

Completely different from the first design — more modern cabinet style. Comfortably houses a standard 25" TV with a huge oversized control panel. The control panel is removable with locking pins, allowing a separate Steel Battalion super-controller panel.

Basic Wood Cut Diagrams

These diagrams show general wood dimensions. Red lines indicate cuts that can be made at the hardware store. Note: drawings assume a 28" cabinet width — I later trimmed 2" to fit through standard doorframes.

Approximate Project Costs (April 2004)

Item	Cost
Xbox CPU	$179 or less
Player 1 Arcade Joystick	$50
Player 2 Arcade Joystick	$50
4×8 ¾" plywood × 2	$39
4×8 ½" plywood × 1	$15
Wood Screws	$9
Wood Glue	$4
24×24 Plexiglas ¼" × 2	$50
Primer & Semi-Gloss Paint	$14
2×2×8s × 4	$8
Hinges and Hardware	$15
T-Molding 200"	$13
Misc. (power strip, cords, feet, bezels, marquee holders, etc.)	$75
25" TV — Sharp 25RS100	$150
Light	$12
Coin Door (eBay)	$30

Phase 2 — Cabinet Production / Manufacturing

March 7 — Purchase and Cut Wood. Trip to the hardware store for wood, screws, bits, glue and primer. Cut all wood into required shapes. Day 1 Pictures

March 13 — Cut, Route and Assemble Side Panels. Trimmed and sanded each pair; routed for ¾" T-molding; installed internal 2×2 supports on two cabinets. Day 2 Pictures

March 22 — Custom Cuts, Trim and Assemble. Built 24½" guide tool to trim all panels down 2" (for doorway clearance); cut TV holes and coin door hole. Day 3 Pictures

March 29 — Assemble Cabinet Frames. Assembled all four cabinet panels to side frames. Coin door from eBay fit perfectly. Received Plexiglas and second coin door. Day 4 Pictures

April 5 — Primer, Paint & Hardware. Primed all 4 cabinets, painted 2. Cut joystick holes in control panels, coin door holes. Added Marquee lights. Day 5 Pictures

April 10 — Paint & Alignment. Finished painting remaining 2 cabinets. Added reinforcement 2×4s and 2×2s, realigned cabinet structures. Day 6 Pictures

April 14 — Plastics. Printed Marquees on Transparency Film. Installed Marquee lights and Plexiglas. Cut Bezel Plexiglas. Mounted Marquees. Day 7 Pictures

April 19 — Assemble Bottom Front. Completed front door/drawer/shelf units; started control panel assembly with carriage bolts. Day 8 Pictures

April 26 — Assemble Control Panels. Completed 2 Xbox and 1 PC control assemblies; completed 2 bezel assemblies; installed an Xbox for testing. Day 9 Pictures

April/May 4 — Completion / Touch-up paint. Completed 3rd Xbox control panel. Added FleckStone finish and clear matte coating. Constructed Monitor base. Assembled and tested one Xbox unit. Day 10 Pictures

May 14 — Delivered. Started mid-afternoon, finished 1:30am. Traveled 217 miles total; delivered 3 cabinets (2 to basements, 1 to office). Rented 17' U-Haul, $52 in gas. Day 11 Pictures — Cabinet 4 with Steel Battalion interchangeable control panel