Minimum/Best Tools for this project are:
Hack saw / Cut off saw
Drill / Drill press
Jig saw / Table saw
Sandpaper / Disk and Drum sander
Hammer / Brad Nailer
(3) six hole keystone cover plates - $2 each
(1) 1/16"x1/2"x3/4"x3' aluminum angle - $4
(1) 14"x9"x1/4" sanded plywood - scrap I had laying around
(1) 1"x10"x12" pine board - more scrap
(2) 6-32 brass wood insert nuts - $1.50
(2) 6-32x3/8" machine screws - $1.00
(4) stick on rubber feet - $4
Keystone plugs - 15@$0.11=$1.65
Loctite Weld or JB Weld
Now we have the tools and the parts, lets get started on the face....
Step 1: Building the Face
Start by looking at the back of the cover plate to determine "Up". You want all your covers running the same direction as it will make it easier to insert your keystone jacks when the time comes.
Next I used a band saw to cut off the ends of the covers. This will reduce the overall size but more importantly it will give us a flat gluing surface. Cut the outside edge of the end pieces so the alum. angle just covers them.
After cutting I squared up the ends using a disk sander and miter gauge.
Next apply purple primer to the edges of the covers, apply cement and clamp together. Use the cement sparingly, it melts plastic. Apply the cement to one surface and press together. When using this on pipe, you turn the pipe a 1/4 turn to set the cement. Mimic this by sliding or twisting the pieces before clamping.
When clamping make sure to keep face flat.
The cement will set quickly but let the face dry overnight to ensure a strong bond. Once dry, remove the clamps and inspect your work. You will probably see purple and cement on the face. Simply get out your sand paper and start sanding.