A little while ago, I was inspired by some work done by a fellow Aussie Arcade member on a series of fight sticks (Link).
After some planning and design, I thought I would try my hand at creating my own fight stick also.
First up was to decide on a button layout and size. I knew I wanted to have 8 player buttons, along with select, start and guide buttons since this is to work on a PS3 and Xbox360 console. I have gone with a top face size of 300 x 200mm. With the side panels added, this increases out slightly. With that decided on, and a button layout, I went about cutting the top panel to size, and cutting out the main player buttons and joystick hole.