Need a little input on a couple decisions

[crashwg]

OK, so I'm building a MINI-GALAGA, it's comming along fairly well albeit quite slowly... and I've come to a couple things I'm just not too sure on.

My control panel will flip down for access to wiring and such.  See attached pics for how I plan to accomplish this.

My first problem is that I need to round-over the edge of the cp to avoid the red line in my arms from resting them on the cp and also because I plan on wrapping the CPO around the curve and a bit down the front of the machine.  I guess that's not exactly the problem, but this is...  The angle on the board I need to round-over is less/more than 90

[crashwg]

And as for how the cp will be flipping...

[abrannan]

My suggestion (You'll need a round off bit and a flush trim bit for your router)

The round off bit should have a smaller curve radius than the thickness of your CP.  

[NoBonus]

You could always just go nuts with an electric sander and/or grinder.

NoBonus

[Doc-]

The only other alternative I can think of is to finish it with some 1/2 or 1/4 round molding.  While the molding would stick out slightly from the CP it would look just fine as long as the overhang was not too large.

As for the rubbing, I recommend carefully sanding both sides of the CP down a bit so you have about 1/32" gap before painting on each side.  Once you paint it it will seal part of the gap up.