Almost every post I've found on how to make one of these things seems to include the line "I am not a woodworker so you'll have to excuse my construction methods." Luckily this is the one part I did understand at the start of the project. There are plenty of posts out there on the intricacies of creating a MAME controller so I'm not going to make this post be a step by step. Instead I'll detail the experience of going from idea to finished product.
I really had no idea where to start though I did know I wanted to do the following;
1) Try out wiring.
2) Not build the entire cabinet.
3) Try out a Raspberry Pi.
4) Keep things cheap.
As mentioned there are a lot of great resources out there for this kind of thing. www.PiPlay.org was a great location for the software for the PI and www.instructables.com had several good posts with the necessary steps.
I did spend a lot of timing trying to figure out the best place to buy the buttons, controller module etc. Amazon.ca had some packages for the buttons but it included a wiring harness and that seemed like cheating. I quickly learned there are very few local electronics stores anymore so online seemed like my only option. I eventually came across www.thepladiumstore.com which caters to the various Playdium's across the country and they had everything I needed. This was when I realized this was going to be a pretty simple project. The IPac2 is pretty much idiot proof.
The measurements for the case were a mix of online research and a cardboard template to figure out what I liked. The plan was for a two player game with joysticks and not too much clutter. I'm not much of a gamer so I didn't plan on downloading any 8 button arcade games or needing a trackball which was rather expensive. This gave me the general layout and a few random measurements for the height and I was ready to build. The case was finger jointed poplar and the top was baltic birch which is a high quality plywood. (I had a scrap piece lying around.)
The button install was very straightforward. I had to buy a pair of wire crimping pliers and I splurged on a better wire stripper. The automatic ones are way better than the manual pair I had. The Pi setup was relatively painless. The hardest part was trying to image the memory card from my Mac. Everything was locked down and it took a bit of time to figure out which security settings I had to turn off. The only issue I had on the inside was that I put in a full plugin and the PI DC converter was offset by 90 degrees so it didn't fit until I added a 90 degree adapter.
I put a few vent holes in the bottom though I don't expect the PI to get very hot. I also had to add an extra hole for the HDMI cord. I do plan on putting a proper HDMI port on the outside but haven't found one I like.
This whole project took about three weeks of evenings from planning start to completion so it really doesn't take a lot of time to get something functional. So far I've managed to install Super Mario Brothers which was my favourite game as a kid. Now I don't have to share with my brothers.