I was able to get the main panel drilled over the weekend. I found a wooden table that was being thrown out, so I brought it home to use as a disposable workbench. Since the table was going to be thrown out anyway, I screwed the main aluminum panel onto it, instead of clamping - this is ensured that it wasn't going to move at all while being drilled. I used a hammer and a regular nail to make a pilot hole for the buttons, and went to town with my hole saw. I did run into a snag when the
mandrel bit broke as I started to make my first hole! Luckily, I had a regular drill bit that I could replace it with. In the end, I had my 8 button holes drilled (using
Slagcoin's transitioning layout by Hori) along with the smaller hole for the joystick.
Even though I had carefully measured the positions for the joystick mounting holes, they ended up being a little too far apart, so I had to slightly bend the panel to bring the holes closer. In the end, it worked out great, since the bend isn't noticeable, and the tightness helps to hold the stick in place even better.
After putting all the guts (hacked PCB) into the PT-10, I was able to test it out online in some Championship Mode fights. I must say, the Sanwa parts make a HUGE difference. Compared to my Hori Compact Joystick, the joystick is easier to move and is more accurate. The buttons are simply the best, since they don't get stuck and are VERY sensitive.
One thing that I did learn from testing, was that the 8 button layout is a little crowded for the PT-10 box. So, for anyone else making a stick with this box, I'd suggest only using 6 buttons or the smaller 24mm buttons, so that the joystick can be placed with more space on the left side of the panel for your hand to rest comfortably.
In Round 2, I'll be drilling the holes in the back panel for the guide, start and back buttons and cutting a rectangular hole for the RJ-45 jack!