advice on polycarbonate (adding cp cover later)

[harveybirdman]

Are there any ingenious ways of ensuring your cp overlay matches your panel f you didn't cut them together or have a template?

[AlienInferno]

Do you mean the artwork or the plexi top?

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[harveybirdman]

Plexi top. I'm thinking trying to make some kind of stencil.

[AlienInferno]

If you have a router you can use a flush trim bit to make the two match.  You would have to be able to remove the CPO top though.  I even used a router to cut out the button holes. (I sandwhiched the plexi between my existing panel and a piece of scrap to cut out the holes).

Also something else that might work is using a piece of poster board or other heavy paper type product.  Remove the controls from your panel, lay the poster board on top, tape it down in a few spots to be secure, and use a hobby knife / razor blade to carefully cut out the holes for your controls and the panel outline into the poster board. You can then use the poster board as a template for your plexi.

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[harveybirdman]

Thanks for the tips, I think I'm going to end up putting a drop cord underneath and shine light up through the panel through sheets from slagcoin.  Once i have a button hole centered over the hole in the CP I'll mark the drill hole on my Lexan (assuming I can see the template through the protective covering.  It might work......