Using a Flush-Cut Trim or Pattern Router Bit – Wedgehead Backglass Frame Project

I ordered a new reproduction backglass for my 1961 Gottlieb Egg Head pinball machine from Shay Arcade – what to do with the old one?

The old backglass had some flaking paint, mostly the purple color at the top. Right way I sprayed the back with Krylon I00500A00 12-Ounce Triple Thick Clear Glaze Aerosol Spray,High-Gloss“>Krylon Triple Thick glaze.

For the frame, I’m going to make a reproduction front and cut it out with a flush-cut trim or pattern router bit.

The original wedge head is approximately 26″ x 26″ x 22″ and is made of 1/4 plywood.

I took a trip to Home Depot and unfortunately they only have the material in 2′ x 4′ precut pieces. They did have a four-foot by four-foot “underlayment” – this would have worked but I couldn’t fit it in my car.

But then I looked online and voila! It seems that this thin plywood is readily available to serve the hobby and laser cutting community. All kinds of sizes are available including 24 inches by 30 inches which will work perfectly.

I measured the thickness of the original front panel on my Egghead pinball machine using my digital caliper and it is 8mm. So I found this piece of plywood that is 9mm or 3/8″ x 24″ x 30″

I will use the original head as a pattern to cut the birch panel with a router and flush-trim bit.

Next, I’ll need sides. I’m thinking 1 x 6 pine for the sides. I’ll notch the back edge to receive the backing board to which a string of Christmas lights will be attached.

The backglass will be held to the front via a couple of small pieces of wood screwed in. Thin foam strips from the back will keep the glass/paint from rubbing against the wood.

Tools used: