Im after a smooth clean finish, my objective is to have no screw heads visible, but structural integrity must not be lost.
To achieve a solid product, without messy joins or visible fixtures, I have chosen to go with the inner & outer chassis design, where the inner chassis will be the mounting platform for all components, and the outer chassis a robust visual shell; aesthetically pleasing.
Inner Chassis dimensions have been determined as follows; Depth derived from the Length of the button component with micro switch attached; allowing 5mm clearance for wire terminals. Length determined based on the popular 6 button schematic layout (shown earlier) & recommended joystick distant. Width via the schematic; and the size of my palm & what I thought felt comfortable.
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