So I documented a Flash Gordon restore here on pinside sometime back that I no longer have. I love Flash Gordon so recently I acquired another FG and decided to restore it. This time I decided to take a different approach. I absolutely love the theme, the art and the colors. That said, I hated the cabinet design. I reached out to Jeff at pinballpimp to see if he could design some custom stencils for me. After a chat by phone I detailed what I wanted. A couple email revisions later I had the cabinet design I wanted. I may be partial but I think Jeff hit it out of the park. For reference here is the traditional design from the factory:

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...And here is what I had Jeff come up with:

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I also have side rails out being mocked-up laser cut with a custom design. As soon as I get them back (any day now so I'm told) I'll post them here. I chromed everything the last time. This time I'm going floss black. I'll be back to update things once I start prepping the cab to paint.

I spoke to Jeff about it. For now, it's a one off. If there's demand (reception here has been luke warm so who knows); it's something he may consider. Wouldn't hurt my feeling to have a one of a kind Flash Gordon.

Thanks guys. I appreciate it. With the black rails, legs and coin door, it will balance all the red. I'm very excited. I have a cpr gold playfield in transit as I type this.

In the mean time, the cabinet is stripped and getting ready to do some repairs, prep and sanding.

Not too bad: IMG_0158 (resized).JPGIMG_0159 (resized).JPGIMG_0160 (resized).JPG

Until you look at the underside. Oops. That's was a surprise. IMG_0162 (resized).JPGIMG_0161 (resized).JPG

So I picked up another empty cab only to find it was damaged by termites. I tore it apart and salvage what I need. Fwiw, the termites have long since vacated. IMG_0163 (resized).JPG

I would love to be able to buy a new empty cab but I will make it look new again either way.

Yes sir. It was perfect timing.

On to the cab. I started trying to repair the hole in the bottom. It's round a quarter sized hole on either side of the vent hole. I would rather not pull the cab apart to put in a new panel so I'll try this first. Like my last FG restore I plan on sanding the bottom which will render it smooth versus the texture but it will be clean. The small gaps at the patched areas will be filled with a color matched filler then the whole bottom sealed. Didn't turn out too bad and it is the bottom so I'll hold judgement for now.

I cut out the frayed edges and attached some blocking to support the patches. IMG_0178 (resized).JPGIMG_0161 (resized).JPG

Pieces in place. I lightly sanded over the patches (glue still drying) to see how well it was going to blend. IMG_0179 (resized).JPG

Glueing the bottom edge that is always split on these games. Sanding has also started. IMG_0180 (resized).JPG

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You would have to move both cross braces and even then it wouldn't work. The metal transformer tray spans those two cross braces. I appreciate the suggestion though.

So I continue working on the patches after the glue set over night. Sanded flat and flush.
Next a little cheat to deal with the small gap on the second plug. Flood the joint with glue. Let it settle and then dump some of the sanding dust in the crack. Work it into place and let it dry. Sand smooth after. The bottom will be overglazed to get everything a uniform color and further mask the edges IMG_0184 (resized).JPGIMG_0185 (resized).JPG
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Replacing the bottom trim that's always broken. I scavenged the lip from the other cabinet since it's already the right thickness and profile. IMG_0190 (resized).JPGIMG_0189 (resized).JPGIMG_0188 (resized).JPGIMG_0186 (resized).JPGIMG_0187 (resized).JPG

Now that the glue is dry enough, time to reshape the vent hole.

Lay out what has to be removed
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And after. Matches pretty close to the other hole now. IMG_0194 (resized).JPG

Comparison of before and after:

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Yeah that's what I did. Then I put the new strip in to replace the broken portion and squeezed everything together. Good as new when done.

I originally tried to wafer a thin piece to set on the damage but it was going to show and the thickness of the recess was too irregular from the damaged areas. I cut the squares as small as I could yet still remove the damaged surfaces. The squares are friction fit with glue as well as a piece of blocking you can see through the vent hole. I have the friction/glue fit so tight, I really don't need the blocking now but I can't get to it to remove it. The patches aren't going anywhere now.

Edit: just to follow up. I found a piece of damage I cut out. You can see where I tried to "tray" it out to set a patch on. It didn't work so you can see how I cut the damage out to get to good wood. image (resized).jpg

Rear done. It's a touch wavy due to the back panel not splitting evenly. Still have some bonds filling to do but structurally it's repaired. Once it's sanded and filled it will look near factory IMG_0196 (resized).JPG

More bottom repairs using scavenged trim from the donor cab.,IMG_0201 (resized).JPGIMG_0200 (resized).JPGIMG_0198 (resized).JPG

Bottom sealed. Now I can see how much color difference there is between the patches and the rest of the bottom panel. Once it's dry I can start playing with on over glaze to get it one uniform color. IMG_0221 (resized).JPG

And a before shot for reference:
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Making progress. Barely noticeable. I could spend another 4hrs and only improve it a percent or two. Not worth it imo. IMG_0227 (resized).JPGIMG_0228 (resized).JPG

Now that the bottom is done and dry, I can flip it over and start on the other side. First up if to glue, brad and clamp the head pedestal. These are always cracked and separated. IMG_0231 (resized).JPG

Then on to the interior sanding.
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Inside bottom done, ready to seal.

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Lots of sanding, filling, sanding, filling.

While that goes on, a little sneak peak...

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Come again?

Oh, lol. I should have recognized what he was alluding to. Thanks.