I bet you thought I forgot about this guy eh?
I did forget to take a photo of step 1 so we'll start at step 2.
Step 1: Control panel is 1-7/8" x 2-1/4" and the hole is 1-1/4" square offset from the right and top edges by 3/16"
Step 2:
cut your 1/16" square strips to roughly 1-1/4". They don't need to be exact as you can trim later. Better to be too long than too short.. Then arrange them around the perimeter of the hole and glue in place.
Step 3:
Fill in the corners with plastic wood. I used waaay to much, but you get the idea.
Step 4:
Clean it all up. I used a dremel with a small sanding drum for the inside corners and a small square file for the outside corners
Step 5:
Now to create the back plate. It's 1-5/8" square. A bit bigger than the hole since you're going to be gluing it to the back. In case you're wondering why I made this part, it's just easier than working on the back wall itself. The back plate will actual sit in the hole I already cut in the rear wall (see previous pics). I'm using square LEDs for the buttons. You'll need to cut out 3 holes at 2mm x 5mm roughly. I drilled to holes side by side with a 1/16" drill bit, then used a small flat file to create the final shape.
Step 6:
Glue the 2 plates together.
Step 7:
Cut a 1-1/4" long piece of our strip of 1/8"x1/16' peice of wood. Place in the center and glue in place. Once finished, water down some of your glue and use a small brush to completely coat the finished panel. In particular the joints. It will fill in the cracks, strengthen everything and give a smoother overall finish.
Just a bit more cleanup and it'll be ready for paint. Then its on to the imitation electrical conduits.
