Sega Alien Syndrome Restoration

AlienSyndrome

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I decided to start this now and will add as progress moves forward. This will be my 40'ith something restoration. ugh Cabinet was in sorry shape, water damage below etc etc etc. You all know the drill. Converted into some fighting game, basically no original parts except for the control panel that had a billion holes drilled into it. Had been kicked in on the side as well, wonderful. Oh well, I love a challenge!!! First off after tear down , stripping the cabinet down to wood.
 

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Next was installing a new bottom, straightening the side wall. Then using wood hardener, glue and bondo , actually came out pretty good. Will be strengthened further after it's laminated. Also had to replace both pieces above and below the back door.
 

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Now to repair all the damage and make everything straight.
 

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Used wood hardener again for the front t-molding channels. Works really good when old particle board material is looking compromised. Began to laminate the front and sides.

P.S. You want to make sure you use "VERTICAL" grade laminate. This is used for the sides and fronts of cabinets. It's half as thick as the counter top grade and thus, your t-molding will in most cases still cover it. If you use the other grade which is thicker, you will probably see the edge of the laminate and thus will need to go with a wider t-molding that in itself will cause other issues. Every game is different. Sometimes the wider laminate will still be covered by the t-molding, but that's because whoever they got their wood for the cabients
that day had a slightly thinner stock to make them from. Also be very careful when handling and working with vertical grade. It's so thin that you can literally tear it by hand. Always measure so you know what your getting into.
 

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After repairing the inside walls surrounding the monitor area, I prime, sand and prime again. Then over a couple days I spray a fine mist layers of Black Satin. After this dries I buff everything down with plain old paper towels which actually are like a fine sandpaper. You want the ones that have a little bit of a bumpy texture. I eventually can almost get it to look and feel almost exactly like the vinyl that is applied over the wood at the factory. The back and back door will be painted by hand using a foam roller. Several coats will be applied over a couple of days and after it dries I use a car buffer and auto wax to buffed it down to a semi sheen and to remove any roller lines that always seem to creep in.
 

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Next the focus was on the control panel. This poor thing had about 18 holes drilled in for buttons and screws to hold down a plexi cover. Now in the past to repair I had used the drywall metal mesh cut to squares to cover the holes. Then I use a piece of clear tape to keep the bondo from spilling out through the mesh. Then of course bondo to fill in the hole etc. This method has proven successful as I've made Black Widow control panels out of Space Duels no problem. BUT like always a few years afterwards someone reproduces the very panel (Takeman) and of course I have to replace it. OF COURSE!!! But I do not think anyone will be reproducing Alien Syndrome panels anytime soon. This was the first time I decided to have the holes welded. And I should have listened to my little voice telling me the panel might warp. Sure enough it did and I spent a week working it back into shape and using bondo. I believe the problem is the cutout windows in the panel and also it's a tad bit thinner than Atari's. I think you could drill and fill a hundred holes in a Gravitar panel and it would still be pretty straight.
 

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Finished up the rear of the game. Need to cut a new door etc. I have to say a big Thank You! to Fizgig for hooking me up with the side-art and cpo who I think is the only one who has reproduced it. Without him doing it this project would have been dead in the water so Thank You!! P.S. Fizgig originally only had one side to scan and therefore no mirror image. Has since updated the scan file and said he would print a correct mirror image for the other side. Again totally awesome!!! Thanks!!!
 

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Im currently building 3 of these and he isnt the only one with the art. Im currently restoring all pieces. With the recent purchase of the newest epson printer I will be able to print the silver ink for cpo also.

By the way the sideart is completely wrong and everybody that bought it will presumably have the same problem. They should be mirrored with Sega remaining the same. Nice looking work on restoration.

 
I will since I need a bunch of them. I got it all scanned in as one piece, so it will be the identical per original. It will be a little bit as I just started cutting the cabinets and then art will be done.
 
I'm having new complete wire dedicated wire harnesses made for this game also if your interested. All this might be a month or two down the road.
 
Finished up the control panel with 5 coats of primer. I'll polish it down and do the cpo tomorrow. For the plexi windows Sega used a thick piece of plexi and then cutaway the excess to fit into the window. I'm having to use 2 pieces half as thick and the window portion will be glued to the larger section that connects to the panel.
 

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Also be very careful when handling and working with vertical grade. It's so thin that you can literally tear it by hand. Always measure so you know what your getting into.

I learned this the hard way when replacing that on my Asteroids kick panel. Tried using jigsaw blades made for cutting laminate but it would just crack the edges, ended up buying a box-cutting looking blade made specifically for laminate. That worked perfectly.
 
Today the control panel was the focus. Installed the plexi window pieces and did a final rub down of the metal and cleaning. Had to bend slightly the posts for one of the joysticks. They had been previously cut off for a conversion and needed new ones to be welded back on. Dropped in and adjusted a new Vision Pro monitor. I know a lot just put a new fluorescent fixture for the control panel but I wanted to stay as original as possible. I ended up sourcing the exact 60 watt bulb lamp fixture from The Arcade Boneyard. I am having difficulty sourcing the fluorescent fixture for the top and marquee. I know it's a dual bulb fixture. Has two bulbs side by side.All I had to go on is a side pic in the manual.
 

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Beautiful Gauntlet in the background of one of your photos.
:)

Today the control panel was the focus. Installed the plexi window pieces and did a final rub down of the metal and cleaning. Had to bend slightly the posts for one of the joysticks. They had been previously cut off for a conversion and needed new ones to be welded back on. Dropped in and adjusted a new Vision Pro monitor. I know a lot just put a new fluorescent fixture for the control panel but I wanted to stay as original as possible. I ended up sourcing the exact 60 watt bulb lamp fixture from The Arcade Boneyard. I am having difficulty sourcing the fluorescent fixture for the top and marquee. I know it's a dual bulb fixture. Has two bulbs side by side.All I had to go on is a side pic in the manual.
 
FYI: When I was rebuilding my Gauntlet sticks, I wanted them to look NOS not all worn down and smooth. So in addition to the rebuild kits I also bought 4 brand new Ball top shafts from Arcade Fixit. So I had the same idea for the Alien Syndrome sticks. I wondered if the company that made the shafts also made them for other applications. Sure enough I was right. Speedlink Sports Tournament Edition Competition Pro USB Joystick and the competition Pro for Atari both use the exact same red top shaft for their controllers. And most of them are not worn down but look brand new. So I sourced 2 of them, dissected them and presto, two new sticks. Also replaced and greased some of the internals as they get worn down over time.
 

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Began wiring things up today and working on the parts to be reassembled. Stripped and sanded the vent mesh and the power inlet box. Will prime and paint tonight maybe.
Decided to reuse the original power assembly platform. Usually I would cut a new piece but over the years I've gotten more into reusing the original parts if possible. Amazing what just a sander can do.
 

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just a quick before and after etc....still have to finishing the wiring.
 

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Have to say a big gigantic "Thank You" to Biomech011 for scoring me not one, but two minty fresh Alien Syndrome pcb's with all new eproms. Sorry I like to have back-ups. I'm sure most of you understand. Three is hording.. two is being prudent!!!
 

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