Step 2: The LCD Surround
1| Strip out the Aluminum case of all of its innards, measure the internal dimensions of the upper case, keeping the sides as straight as possible so you get an accurate measurement.
2 | Using the measurements cut a rectangle from plywood and shape it to fit inside the upper half of the case. I used 3mm 3-ply plywood as this is what I had to hand at the time, you can use just about any thickness you like. Be aware that there are some aluminum rivets which hold the case together. You may need to make grooves in thicker plywood to make room for them.
3 | Centre the LCD panel on the board, and mark the area to be removed so the screen will fit inside the plywood. It is worth measuring the visible area of the screen and taking the time to correctly align it so that the visible area sits in the center. There will also need to be a cut-out for the menu board.
4 | I have used some scrap veneer and glued it to the from of the plywood. The veneer should exclude the LCD metal surround from view and leave only the visible area viewable.
5 | Check the wood panel still fits tightly inside the upper case.