How To Plug Holes In A Metal Control Panel

Hi!  If you convert cabinets between games with different controls, here is a frequent problem - how to plug the extra unwanted holes in a metal control panel.

Over the years, I have experimented with several solutions (except for spot welding).  None were as simple, inexpensive, and permanent as the one I explain below.

You can click the photo images for a larger view.

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How To Plug Holes In A Metal Control Panel:

1.   Problem.  There are too many holes in this control panel. 

You can use a solid sheet of clear plexiglass to cover the panel surface.  But, over time plex gets scratched and nasty.

You can plug smaller round holes with button plugs, or with carriage bolts.  But, that does not make for a neat playing surface.

Or, you can plug the holes with Bondo (as is shown in the photo).  But, Bondo alone will break loose.

So, how do you back up the Bondo to form a rigid permanent panel surface (without spot welding)?

2.  Solution.  You can back up the Bondo with shaped pieces of Formica, and Masonite (as is shown in the photo).

Clean and scarify the metal surface.  Apply 3M 77 spray adhesive to the metal.

Apply 3M 77 to the rough side of the shaped patch.  Allow the adhesive a moment to dry, then press the two coated areas together.

The Bondo can then be applied to fill the unwanted hole.

  3.  Finished.  An out of sight, permanent fix, as described above; allows for a sleek, new looking control panel. 

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