NES coffee table update 3: Making the D-pad

The hardest to make so far on the NES coffee table has been the D-pad.
Because it's multi directional, it can't just be a straight push button like the others, this brings up a few complications, mainly with friction and bits rubbing together.

To actually model the D-pad, I started by cutting out the pattern on the top in some of the 4mm MDF, again using a blunt graphics scalpel (I really should have invested in a good Stanley knife or something).

I glued it onto a cross I cut out of the 18mm MDF.

Then took to it with some sanding paper and gap filler to give it a nice curved look to it.

As I mentioned, actually making it work was the difficult part. I started off just like the other buttons, with one bolt on each arm, a spring on each bolt and a washer to act as stoppers for the springs.

For the backing plate I put a screw through the centre for it to rock on, and so opposite directions couldn't be pushed down simultaneously.
I also had to drill the holes a lot bigger to accommodate for the distance that the bolts will travel when they twist and rotate (that's why I needed the washers, because they would otherwise fall straight through these holes).

Here is the the prototype I made before making the actual button.

It is able to rock from side to side, up and down, and diagonally as well. It also seems to be very sturdy and ready to take a beating.

This is the final button, constructed.
Next step for me to do is to mount the buttons in the lid of the coffee table and make sure they don't rub or catch on anything.

NES coffee table update 2: Making the buttons.

With the main part of my NES controller coffee table basically constructed, I was finally able to find the right sized hole-saw in my dads garage (it's basically impossible to find anything in there, seriously look at how much of a mess it is in the background of some of those pictures in the previous posts), it was time to make the A and B buttons.

I don't know whether I mentioned earlier, but besides just asthetically looking like a NES controller, I also wanted the buttons on it to work (and when not being played a large piece of glass sits on top of it so it can be used like a regular coffee table; to place stuff on).

They key to making the buttons for this was sturdiness. I've got some pretty retarded friend who are probably ready to go to town on this thing, so it needs to be able to stand up to a good beating as well as remaining easily playable.
Above is my fantastic 5 second sketch of how the buttons might be constructed.

After cutting the buttons roughly, and cutting a backing plate for them, I drilled 3 holes through the plate and half way into the buttons, I then got 3 quarter inch bolts per button, cut the heads off them and hammered them into the button.

I also bought a few small springs to go over the bolts like so.

Next up was to drill the holes in the backing plate a bit larger so there is minimal friction between the bolts and the plate while still guiding the button properly.

The button is positioned through the backing plat and nuts are put on the bolts to stop the button from coming out.

And there you have it, one sturdy, working NES button.
After if figured out the proper mounting, I will probably use just some big strips of copper as the contact points for the button. Otherwise, maybe buy some push buttons from dick smith and mount them in there.
In the next post; how I constructed the D-pad (that was a whole lot harder to do because it has to rock in all directions).