Another day, another huge update.  I thought I would take more time getting this project done, but as it turns out, I’m pretty impatient.  I hardly got any sleep last night.  I kept thinking I would get just one more thing done.  Well, indeed I did.  Sometime early this morning, exhaustion and a blurry vision took over, and I stopped to get a few hours of sleep before work.  In fact, I don’t think I really realized how much progress I had made until I came home tonight.  Anyway, on with the pics…

Here Is the plexiglass that will fit in the LCD opening.  I had this made the same time as the front panels.

Who doesn’t love modder’s mesh?  I’ve got a whole sheet, but only need a little strip.  I’m already thinking of creative ways to use the remainder.

Here I have the LCD brackets and modder’s mesh applied to the back of the main panel.  A little superglue was all that was needed.  I attempted to remove one of the smaller brackets to reposition it slightly, and any doubts about the superglue’s strength quickly vanished.  It’s on there to stay!

I’ve installed the plexiglass.  It fit perfectly snug.

While the plexi is unlikely to move, I used small drops of super glue to hold it in place from the back side.  Caution is needed here to make sure the superglue doesn’t get on, or fog up the plexi.

Here the LCD is mounted to the panel.  The used of small bolts mean that it can easily be removed, should it ever need to be.

This give you some idea of the amount of plastic that needs to be removed from the bezel in order for the LCD to fit.  Care must be taken not to damage the switch assembly during cutting.  I wouldn’t advise cutting anymore than this, as you will need all the remaining plastic for mounting of the switch assembly.

This is all that is left after the switch is cut out.  There’s a fine line between leaving enough plastic on the bezel, and leaving enough on the switch.  Also, there isn’t much room between the LCD and the switch, so make your cuts count!.

It just fits!  Any further to the left or the right, and the switch won’t clear the bezel when the panel is put in place.

Here is a good example of the detail put in to the FPD part of the process.  I used countersunk holes to achieve the beveled edges around the switches.  This must be designed in to the plan at the time it is drawn up.  Any attention to detail is critical, and no detail is too small.

Here’s a little bonus I brought to the party.  It’s also part of the reason the project was called Alpha Blue.  I mounted some EL wire around the outer edges of the bezel.  Once the panels are in place, there should be a faint blue glow from behind them.

The obligatory shot in the dark.

This is a view from behind with everything but the switch buttons and LED’s mounted.

Here is another shot from the front.

At this point the project is about 80% completed.  I may actually have to get some sleep tonight, but I’ll hopefully have more updates for you all tomorrow.