Putting it Together
Now that your parts are complete, it’s time to put them together! Before actually assembling everything, it may be a good idea to test the fit of all parts before proceeding. This will allow any errors to be corrected before they become a larger problem.
Preparation
The plates will be attached to the frame using screws. To make this easier, pre-tap the holes for each screw.
(1) Line up the plates on the frame.
(2) Using the holes in the plates as guides, pre-drill holes into the frame. Make sure to use a drill size smaller than the screw you will be using to ensure the threads will catch.
Fit the buttons
Each button has a different style of attachment. The buttons used here have a screw on base and upper lip that sandwich the button onto a hole in the acrylic.
(1) Unscrew the holders from the buttons.
(2) Line up the buttons within the holes on the plates.
(3) Screw on the holder from below.
(4) Attach the microswitch (and LEDs if available) for each button.
Fit the Encoders
Rotary encoders will be srewed on to the top plate. The knobs will be attached to the shafts after the encoders are attached.
(1) Line up the rotary encoder on the top plate. Ensure wires are facing inwards to avoid collision with the frame.
(2) Attach with screws to the plate.
Attaching the Plates
The middle and top plates will be attached to the top of the frame. The bottom plate will be attached to the bottom of the frame. Do not attach the bottom plate until everything is completely done. You will need access to the wiring until the controller is functioning properly.
(1) Align the middle plate and top plate on top of the frame. Ensure parts do not cause collisions with the frame.
Note: My initial design failed to account for the space on the topmost button. A router was needed to cut out a pocket in the frame for the button to have space.
(2) Attach the plates to the frame with screws.
The Bottom Plate
The bottom plate may be held in place with tape until access to the interior is no longer necessary. Mount in the same manner as the other plates. Rubber feet may be affixed to the bottom plate to provide grip on a table surface.
Next Steps
The controller is nearing completion! It just needs wiring and programming to be functional.