CPO question

[gman314]

Let me first say that I am a newbie building my first cab (a bartop).  I am confused as to what is the method of installing a CPO.  First of all, I have to make the holes myself.  Now, what I'm thinking is that I will first attach the CPO to the CP (with adhesive), and then make the holes (so that they will line up).  Does this sound correct at all?  Also, as far as the holes go,  do I drill them into the CPO, cut slits into them, or is there a better method?  Finally, the front edge of my CP (the part with the T-molding) is slightly curved.  What is the best method of making a perfect cut? 
What I need is either some advice or a simple step by step.  Thanks alot in advance 

[Hemi]

You should not use the same wood hole drilling bit to cut holes in your CPO as you used to cut into your wood CP. You have to use something specifically designed to cut into plastic.

As far as the T-molding goes, cut the bottom edge a few times (the edge that would be hidden up in the mdf) right next to each other where the bend is needed so that the molding has room to bend freely without having to twist or bend into itself. Making cuts or tiny gaps in the molding allows for easy bending in curved areas. The cuts should not be in the part of the molding that is seen, but the part that is buried into the router space.

Hope that makes some sense.

[javeryh]

1.  make sure your artwork/CPO has center points on all the buttons and joystick holes.

2.  line up your artwork/CPO on top of your CP exactly where you want it to be and tape it down securely so it won't move at all.

3.  using an awl or nail or something pointy and your hammer, tap the awl or nail or something pointy on the center points of all the buttons and joystick holes.

4.  remove your artwork/CPO.

5.  using a foerstner bit (or spade bit) drill out the holes using the indentation in the wood you just made as the center point for the button and joystick holes.

6.  secure artwork/CPO in place permanently.

7.  using a razor or something sharp, cut out the button and joystick holes - the bezels will hide any imperfections with your cuts.

8.  install buttons and joysticks.

[gman314]

Thanks for the advice, but I'm still a little confused about the bend in my control panel.  It bends slightly outward in the front.  In other words, it does not line up perfectly with the vertically mounted piece of wood directly below.  What this means is that I can't make a straight cut (say something like 11 x 7) of the CPO.  Although the sides of my control panel may be about 11 x 7, the center part is about 11 x 8.  I'm assuming that I will have to make a curved cut of the CPO, but what is the best method of doing so?  Thanks.