Beaker - I love your custom facia. If you want to work something out to get it cut, let me know. And damn, you got my setup almost exact. For clamping I use mitee-bites on a piece of aluminum stock that will be used as scrap. Than I super glue the aluminum used for the facia to the scrap. This way I have no clamps in my way and I can machine all the way around without worrying about hitting anything.

First I machine the backside
- cut inset for lens
- rough cut button holes
- finish buton holes with bevel

Front side
- drill bolt holes
- countersink bolt holes
- 3d contour rough
- planar finish

- Polish with various wheels on a high speed hand drill

Rob