Worked on a couple things today. I was really nervous about cutting the acrylic for the CP. I used some stuff called Optix that I got at HD, it's a bit cheaper then lexan and has similar properties to plexiglass. It is somewhat prone to crack however, and I did crack another sheet when working on my marquee. The idea behind cutting this stuff is that you score it several times with a special blade than 'snap' it with a bit of pressure to get a clean break. I was especially paranoid about cutting the hole for the trackball as I didn't want to buy a $20 3" hole bit. So I took my chances with a router and a mortising bit. While this stuff can be routed cleanly, you've got to be really quick as it will melt in no time flat and leave you with a really bad edge. I managed to route the hole by starting a pilot hole and routed by having the bit shaft rub against the profile of the trackball mount that was in place while routing, this resulted in a perfect circle to the exact diameter and placement that I needed.
I made a design mistake with bezel design in that I left a gap at the bottom where the CP meets the cabinet, to rectify this I simply cut a ~3" strip to attach to the bottom that will meet flush with the top of the CP and provide a shelf for the plexiglass to rest on. Lastly, I made a shelf for the TV and placed some blocks at the back to keep the TV in place. I would go with something more secure but it's doing a good job holding and serviceability is important to me. Besides, I don't plan on moving the cab for a loooooong time. Only some paint touchup, CP wiring and bezel work to go!