Dan's Workshop, a Maker Blog: WC Mini Arcade Build

A while back I had the idea of creating custom arcade versions of classic PC games.

For my first attempt at this I choose the 1990 space combat game "Wing Commander."

Why Wing Commander?

It was the game that kicked off my addiction to 90's PC games.
1980s comic book style artwork that is still fun to look at.
Simple enough control scheme to layout completely without having to use a keyboard.
Matching control schemes across multiple games: Wing Commander, Wing Commander 2, and Privateer.

The first step was to figure out how to map the controls. I'll be using a CH Fighterstick, which can hold a ton of functions on it's 5 hat switches and 4 buttons.

To compliment the fighterstick I'll be using a USB joystick controller which adds another 32 buttons.

http://www.leobodnar.com/shop/index.php?main_page=product_info&cPath=94&products_id=205

To make all these buttons work with the games I'll map the functions using the app "Joytokey"

http://joytokey.net/en/

I compare WC, WC2, and Privateer and come up with a control scheme that works for all of them.

Next is to source the buttons. I search ebay and find a lot of inexpensive lots from China, it will take a while to get here, but it's a lot cheaper than buying from my local electronics store:

I create a rough mockup in Maya to decide on control layout and general look, I'll add more detail as I build it:

To get a general idea of overall scale:

The digital part of the planning process is done, now I just have to wait for the parts to arrive and then get building.

Parts Arrived!

After measuring the actual size of all the buttons, I create the final model for the control panel. It's then broken up for printing on my 3d printer:

First print successful, this is the lower left panel.

I'm printing in ABS for strength but keeping these large flat parts from warping is a challenge, my solution was to setup a thermostatically controlled circulated heat inside my 3d printer. This part warped a little, so I've increased the chamber temperature, and so far the subsequent parts are coming out perfect. Once I fit all the parts together I'll decide if I need to reprint this part or not.

All the parts are printed ready to be glued together:

Glued together, ready for finishing and paint; the joystick is going to bneed to be mounted a bit further back than planned, otherwise it will collide with the panels in front when pushed foward--this is a measurement I had not accounted for (there's always something that gets missed):

Due to the size of this project, and my lack of space in my house. I'm beginning to reconsider a full arcade machine build, instead I think I may turn this into a custom controller only. I can build it into an arcade cabinet later if I ever happen upon more space.

Primer:

Paint, print layers and glue seams are more noticeable than I hoped, but I'm going to weather this in the end so that should mask these imperfections:

Buttons added:

With Joystick

One challenge was figuring out how to do the lettering, I considered buying a vinyl cutter. Ultimtely I decided to 3d print some stencils. This won't create prefect results, but since this is supposed to looked used and weathered, it should work.

Starting working on the base, built from MDF:

Painted base, added wii 12v powersupply for the lit buttons:

Toggle switch on the front will turn off the lights behind the screen and buttons:

Wiring is done, and it's ugly. One of these days I'll learn to do pretty wiring. The top and the base are connected through a detachable connector for easy servicing.