I finally love building this unit. What was once a frustration is now a creative outlet. The Elite calls for much more tight tolerance work. I even thought I'd need a CNC machine, but the x / y axis drill press vice, 3 dedicated routers and jigs, as well as a simple table saw sled, has allowed me to achieve an extraordinarily high level of accuracy, without too much fussing. Once frustration was eliminated from the process, it became fun.
I've also gotten really good at hand sanding / shaping / filing wood. If you saw my file collection you'd laugh. It can be difficult to buy a single file, most often they come in sets of 10 or so. I must've purchased 6 or 7 different sets of small files, diamond files, and rasps, in every shape and dimension. All in all, must be close to 100, and I probably use 10 or 12 most often. The less I can chisel (chisel knife), the better. If my work with the router is good, filing is minimized.
So, good news! Alan's package of buttons and mesh for coils has arrived, even on this holiday weekend, priority mail got it here in two days. I'm ready, having formed another sixteen perfect cover plates. With this batch of cover plates hand selected the piece of cherry that I wanted to use. It has the perfect grain pattern to maximize strength and minimize edge roughness.
I would like to pre mount the board to the cover plate with buttons and screen totally functional, and never disassemble. Unfortunately, I have to wait until after pre-assembly of the unit, where the cover plate gets final fit and mounted. Then I can disassemble the cover plate from the unit and attach it to the board. Now the cover plate / board / buttons / screen / which is already fit and mounting holes tapped, can be final assembled.
Hope that makes sense...