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I am building a M.A.M.E. (multiple arcade machine emulator) cabinet up here at Techshop Detroit and I needed to make a bezel to frame up the monitor.  Here are the steps I took to make this one nice and clean

.http://www.techshop.ws

Step 1: Gather You Materials

Start with a 4'x8' sheet of MDF and a 4'x8' sheet of black ABS plastic.

Measure the length and width of the TV as well as that of the TV screen itself. (pictured with bezel already in place)

Step 2: Making the Mold

Cut the four sides of the mold on the panel saw.
Measure the four sides for the exact length and width needed for the TV.
Use the chop saw to cut the 45 degree corner angles
use the table saw to make 45 degree bezel cuts along the length of the sides.
Use the pneumatic brad-nailer to connect the sides.
Try fitting the bezel model around the screen to make sure the fit is perfect.

Step 3: Vacuum-Forming the Part

Measure out a piece of plastic big enough to fit the opening of the vacuum former.  Cover the mold with baby powder to aid removal from the plastic. Place the bezel mold into the vacuum former.  Heat the ABS for about 80 seconds and form the part.  Pop the mold out of the plastic bezel.

Step 4: Cutting to Fit

Use a Hand-Jigsaw to cut out the center of the piece.

Place the bezel against the screen to check for fit.

Use the razor to trim the bezel to a perfect fit.

That's it!  You now have a slick, clean bezel to make your arcade cabinet monitor or TV screen look professionally installed.

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