Haven't been able to work on the cab recently as I have been busy playing Rygar! I am really digging my cab, it is such a cool thing to have. I have played it every day since the control panel was plugged in.
But... This week I did make
some effort. Through a company I deal with at work (being a purchasing officer has its perks), I sent off some plans for Lexan sizes I needed cut & supplied. The dude has a CNC lathe and his business is plastics engineering. I wanted my dashboard Lexan to have a slight corner radius which I could not achieve with my own tools.
At the same time I gave him my required marquee sizes. I still have Lexan leftover but it is a bit scratched up so I decided not to use it. Besides, I just spent a whole weekend cleaning my garage.
The dashboard setup will consist of a top 3mm layer of Lexan where the corners and edges have been slightly rounded, then I will have an instruction card or the cabinet logo or some other artwork, then a 6mm piece of Lexan the same size as the top part, and finally.....A small piece of Lexan to spigot the assembly into the dashboard access panel.
Confused? Refer Pics. In the photo you can see the approximate position of the dashboard Lexan sitting on top of the vinyl.
I will have to use screws to hold the pieces together and I see no way I can do this without them being exposed. I have decided to countersink and screw from underneath and dress the top with some shiny acorn nuts. Rather than try and conceal these nuts, I might try and bring them into the artwork so they don't look terribly out of place.
I have not completely dismissed the idea of back lighting this section. I need to check it won't cause any glare on the monitor and then make a decision. I envisage the artwork will be a few images and text on a black background so all I really want is a subtle glow. I am even thinking the clustered LED's might be suitable..... More thought required here.
For anyone interested, I asked the CNC dude how he holds such small pieces for machining. He explained the CNC bed is a giant vacuum with little holes that suck down the workpiece. No clamps required! Cool....
Best of all I got the work done free of charge!

Big thanks to
Aiden from
Starwheel Manufacturing.