My process for making Jaguar cart dust covers

[Saturn]

Was looking for an online resource in case my hd ever crashes or it's another 20 years before I need to make one. This is what I came up but if anyone can improve on any part of the process, please do

Items/tools needed:
12" ruler (single use)
tape measure
pen or pencil
scissors
8.5x11 printer paper
3/4" wide black electrical tape
.72" wide popsicle stick or tongue depressor (can be bought for almost nothing in packs from WalMart or dollar stores' crafts sections)
Scotch tape
Wire cutting pliers (or some other way to easily cut 1/16" wood)

Steps for making the templates: (one time deal)
Made a rectangular template out of thicker/stronger paper cut at dimensions of 9-1/2" x 1-1/8"
Drew "fold" lines across the 1-1/8" width @ 2-1/4" , 2-3/4" , 6-15/16" , 7-9/16"
Drew reference marks at 3/8" from bottom edge on both ends
Marked a popsicle stick at 4", then cut it for a template

Steps for making the actual covers:
1. Tear off and place 2 small pieces of Scotch tape nearby (conveniently placed to manipulate w/ one hand later)
2. Outline the template on a regular piece of 8.5 x 11 printer paper. (also place marks @ fold lines and 3/8" locations)
2a. Draw a line from one 3/8" mark to the other down the length of the paper for reference later.
3. Mark a .72 inch wide tongue depressor or popsicle stick @ 4"
4. Cut out the paper outlined by the template
5. Pull out enough length of electrical tape (about 12") and let it sit for a few seconds to retract to a relaxed state
6. Line the top edge of the cut out with 9-1/2" of 3/4" black electrical tape @ the tape's 3/8" halfway mark
7. Using scissors, cut along the fold marks approximately 3/8" at the 4 places marked
8. Turn the paper around and cut into the electrical tape 3/8" (until you reach the paper it's adhered to) directly across from the previous cuts. It doesn't have to be perfect so 'eyeballing' it will be fine.
9. Fold the tape sections over the top of the paper and affix them on the other side, creating a taped edge w/ splits all the way down the length on that edge.
10. Take a Jaguar cart with the label facing the the widest part of the paper and wrap the paper around it with the ends meeting near the center rear of the cart.
11. Line up the upper electrical tape edges and lightly remove any slack but don't pull it too tight as it will be difficult to remove the cover later.
12. Take one of the small pieces of Scotch tape and secure the electrical tape edges together
13. Turn the cart upside down and line up its bottom edge w/ the 3/8" line drawn at step 2a.
14. Fold the split edges of the paper down like a box top
15. Use the other piece of Scotch tape to secure the four 'flaps' in the center
16. Check the front of the cart with the electrical tape edge to ensure it runs evenly across the face of the label
17. Pull out enough length of electrical tape (about 6") and let it sit for a few seconds to retract to a relaxed state
18. Starting about 1/8" under the electrical tape upper edge on one side of the cart, press the electrical tape around the bottom of the cart's newly attached paper, and up the other side. Cut the elec tape about 1/8" under the upper edge (to match the other side)
19. Pull out enough length of elec tape to encompass the entire cart (about 10") and let it sit for a few seconds to retract to a relaxed state
20. Starting at the middle in back of the cart, stick the tape about 1/16" under the top edge of the 'folded tape' and without stretching it, run the tape around the cart, covering up any visible white paper, to meet again at the starting point
21. If all white paper areas are covered, gently & evenly press along the tape to secure it
22. Slide the cover off the cart w/out destroying the somewhat fragile integrity of the encasement. (if it's difficult to remove, try a less tight wrap around the cart in step 19)
23. Cut the marks on the popsicle stick from step 3 with wire cutting pliers (cut with the smaller piece facing into a garbage can as the force from the 'snap' when it gives, will launch the fragment in the opposite direction at about 30mph lol)
24. Check/measure to make sure the remaining piece is 4" or (even better) just under and that any rough edges/splits are filed down
25. Place the modified popsicle stick into the dust cover and press it down against the bottom to firmly seat it into position
26. Place the dust cover back on the cart

[Shadowrunner]

Wow, now that's hard-core! Very creative

[zapiy]

Thats awesome work fella.. Actually a very creative solution for a big issue.

[Saturn]

Thanks guys, yeah it was a problem for decades and all the research I'd done was fairly useless overall. Just a bunch of ideas that were already in place for other systems using old 8-track cases and things of that nature. Not really ideal for the Jaguar carts with the odd shape and size difference. Then one day I just started messing around and got lucky enough to do this. Seems a little generic but definitely solves the problem so I'm quite happy with the results.
All the carts I leave loose to play often have these covers and there have been no contact problems since when inserted.

[Saturn]

Been making a lot of dust covers lately and bought a new peg board from Lowe's this past weekend to test out placing more games on a single sheet. This one isn't molded fiberglass but is flat. 24"x48" and about 1/8" or 3/16"" thick. I've got spaces for 60 Jaguar carts on this one and thinking about taking the majority of my collection out of their boxes to display on it.
Can't wait to get this mounted on the wall so it's the first thing I see when I enter the game room

[Shadowrunner]

Sounds great! Take some pictures when it's all done

[Saturn]

Will do. Hopefully this will make it easier to access my carts since everything is scattered. Boxes of Jag stuff all over. Hoped the Skunkboard would be the solution but it doesn't cut the mustard in every instance so plan C is rising.