Follow up questions on Plexi and MDF

[DeafBug]

I have read the last several pages with interest but it somewhat stop short so here it is.

I have seen several posts on painting or whatever with MDF.  Some did it, other say paint don't hold on good. What is the best thing to do with it?   I was thinking of getting contact paper and wrap around the edges and staple it on the bottom so it holds.  But then again I can see it get worn out especially at the corner.  If I round my corners, then the contact paper won't come out nicely.  I know I can do T-molding but this is at the control panel.

Speaking of control panel, I have not found a 5/8.  I got a 3/4 MDF shelf board but I don't think it is big enough.  Home Depot sell a 2x2 1/2" thick which is just fine. Menards sells 4x8 1/2 or 3/4 MDF, too big.  And Menards sells 3/32" thick of Lucite Tuf.  Add them up and it is just a tad short of 3/4. (This is cheaper method for me than using Lexan.) How hard is it to do the cut with the molding.  I saw a tip on using the table saw to make the groove. That will do for me.  I am also making a keyboard drawer under the CP.  I could use the rest of the MDF I have for it but how does it hold on paint?

As for the plexi products or whatever plastic you get, I saw several posts on sanding it to smooth out the rough cuts.  What do you use to sand it?  If they are tough, can you sand it by hand? Or do you need a Dremel?