1) Which order do you think is best for a new control panel. I'm thinking
Plan the size of the CP
Create the Artwork to match the size with the button holes first
Drill the button holes and others based on the graphic ---- (I learned my lesson from trying to add art after)
Check out the design process here in the FAQ. 
Scott
Did you mean #11 only?
"Design the rest of the cab around the monitor and control panel. The control panel and monitor often dictate the required dimensions for the rest of the cabinet. Keep also in mind the considerations at point 1 in this list! "
Because the FAQ has only 3 mentions of certain keywords (hole as example) that would discuss about how to design the graphcics to fit the wood, or the wood to fit the graphic.
I've already built and torn down a cabinet. Wired 2 light guns, 20+ buttons, Xbox controllers, etc etc. I'd like my new cabinet to look a little more "retail" if you know what I mean.
So what i'm wondering is how do others plan their control panels?