I've been trying to decide what to do for my build coming up shortly. If I'm reading things right; the current consensus (as much as there is a consensus around here

) is to just cover the control panel with a nice overlay that is laminated (polycarbonate if I remember correctly). This is what the arcade machines of yore used to do before they started covering them with plexiglass. I think the plexi is more difficult to keep clean an scratch free, so I'm pretty sure I'm going to just go with a nice overlay. I also plan on using 5/8" plywood and then I'll put a 1/8" plexi or mdf on top of that with the overlay attached to that. That way can remove the overlay to service things if need be.
As to the thickness, I'm not sure that matters too much. If you want to use t-molding for trim, then it might be easier to get 3/4" molding. But, it does come it lots of sizes.
