Benheck first (possibly last) annual Bondo open!

Post by **Triton** » Fri Mar 16, 2007 3:15 pm

If nobody is done, I see no reason why it shouldn't be extended. You all have until Sunday.

G-force · Post by **G-force** » Fri Mar 16, 2007 3:26 pm

Curse bondo drying times. With all these multiple coats... This is taking forever.

Post by **Triton** » Fri Mar 16, 2007 3:39 pm

lol my spot putty dried fast! woo, i need to sand this last coat i think and i can get to painting!

Post by **Skyone** » Fri Mar 16, 2007 3:49 pm

Just a little bit more...

Gump-in-space · Post by **Gump-in-space** » Fri Mar 16, 2007 5:02 pm

Cool, I was going to use my dad's dremel for the job but he didn't have any cutting disks. Now I have a bit more time.

Dark Lord · Post by **Dark Lord** » Fri Mar 16, 2007 5:03 pm

crap i have to rewire it again

i am going to tape the buttons in if i finish the case in time and rewire it this week

just applied the last of the bondo and it is drying right now. I will start to finish sanding it tomorrow and hopefully will get it primed and painted by sometime on sunday and if i dont i will post pictures when it is finished

what time is the deadline on sunday?

EnterTheHatrix · Post by **EnterTheHatrix** » Sun Mar 18, 2007 9:07 am

2 days later.... Is anyone ready to submit? Because I'm not.. I've had to spraypaint my girlfriends laptop, and because I want a perfect job, I haven't been able to do anything else in the shed, which has limited progress... As far as functionality goes, it works..

I've also got another which is far from finished, which was my original submission.

Turbo Tax 1.0 · Post by **Turbo Tax 1.0** » Sun Mar 18, 2007 9:24 am

i guess i'm done, but its just the case with the pc board inside holding the buttons

EnterTheHatrix · Post by **EnterTheHatrix** » Sun Mar 18, 2007 9:35 am

OK so we're sumittng pictures now?

EnterTheHatrix · Post by **EnterTheHatrix** » Sun Mar 18, 2007 10:37 am

If nobody is submitting, then I will.

I started by cutting out a circular shape.. No idea what I was going to do yet..

Then I cut out a back piece.. I'd hoped to have a nice front panel to display, fully lit up and everything.

I measured out roughly where everything would go, and drew it on the plexi glass.

http://img254.imageshack.us/img254/5726/img0041na7.jpg

I ended up rounding the board so the case didn't get thin edges..
http://img254.imageshack.us/img254/5589/img0043na4.jpg

I decided to rip apart a case, and build a one handed NES controller at this point..

http://img254.imageshack.us/img254/8913/img0044vk0.jpg

http://img254.imageshack.us/img254/517/img0045lg1.jpg

I bondo'd the case in place, but obviously, lots of leaks went through so I had to cut them out.

At the same time, I had an idea to have a transparent piece in the middle and shine light through it.. Lack of red LED's meant I'd have to improvise with red CD marker and sand paper.. So I cut some groves on each side as a kind of decorative thing, and to show the shining lights when they're on.

http://img254.imageshack.us/img254/6225/img0049sx3.jpg
Meanwhile, I decided to cut holes for the screws, and I started screwing the case together..

Those screws were crap though, and rounded out really easily, like they were made out of lead.

http://img267.imageshack.us/img267/2438/img0046bx6.jpg
After more sanding and bondoing, I had a really nice finish...
... Until I started fitting the pieces.. The bondo just came away from the NES controller front face. I made several attempts to repair it, which I could have done with fibreglass, but the rule probited it, so I ended up supergluing it with about 30ml of superglue (I went through a whole bottle).
This seemed to do the trick, so I sanded and applied the little bondo I had left.
Then I had an accident!
I grew impatient of waiting for the bondo to dry, so I used a heat gun.. Unfortunately, I warped the plastic, so I had to redrill the buttons to ensure they fit properly, and fill in with more bondo, and sanded more..

Then came the spray painting..

I painted it with grey primer, sanded, primed, and then sanded some more.. Then I used some cheap ass Â£1 glossy black.. This ruined it.. The surface was crap, it didn't dry properly, and it made the bondo stand out really badly.

I left it as it was until today, when I sanded a bit of grey fleck that accidently hit the NES controller.. After using Silvo to shine up the case, I noticed it has a really nice, slick, shiny finish, so I decided to sand it more with 1200 grit sand paper, and shined it up with Silvo (silvo is a silver polishing compound.. Great for cleaning up plexiglass

scratches).

The finished top.

Finished assembled.. You can see the frosted plexi in the grooves in the sides.. There's a dark red piece behind it, which only can be seen through with intense light, so that kinda sucked!

http://img267.imageshack.us/img267/6093/img0080td1.jpg
The seperate layers..

Notice the knotches where LEDs sit to light up the layer.. I also haven't drilled for the black inner layer piece because it was a late addition to the project, but not really required.. It just lets the plexi in front of it illuminate beter.

The back piece has a piece of foam strip to push the board to where it needs to be.
There is an extra groove on the inside of the back piece because I started cutting from the wrong side for the wire pins to stick up.

My other project was a single handed controller, but after someone said they were doing one, I made it less of a priority.

I used a small thumbstick attachment I had for my old GBA, and I cut it to pieces and grafted some plastics on to it and made it into a small "fits in your palm" NES controller shell.
http://img443.imageshack.us/img443/1786/img0076gl0.jpg
http://img443.imageshack.us/img443/8840/img0075rc5.jpg

Slightly awkward to hold, but I was going to have an elastic strap around the back to keep the controller on my fingers.

More pictures.. I've sanded it down and polished it further..

BenHeck.com forums reflection (obviously obscured by the concaveness of the controller)

Blank notepad document.. If you look carefully you can see my taskbar quite clearly, so it proves how reflective it is.

Front ways

Top ways.

LED's...

The pictures do the LED's no justice..

On both sides..

I'll take more pictures when it's light..

G-force · Post by **G-force** » Sun Mar 18, 2007 11:04 am

That looks great! I almost thought you had used a PSP case shell for a minute there

Mine is not even close to done I'm afraid. Still in the primer stages, lol.

Post by **Triton** » Sun Mar 18, 2007 11:16 am

same with me!

Turbo Tax 1.0 · Post by **Turbo Tax 1.0** » Sun Mar 18, 2007 11:31 am

i guess i'll post mine too then, i gotta upload the pics first

Turbo Tax 1.0 · Post by **Turbo Tax 1.0** » Sun Mar 18, 2007 11:44 am

in this picture you see most of the gap because its not screwed together yet i didn't put the l or r buttons in yet either

not much to the guts right now, or you could say there are none

Unidentified Assilant · Sun Mar 18, 2007 12:05 pm

Both controllers look awesome!

I thought you was all making NES controllers?