Step 3A replica CRT screen.
First we need to make a perspex front for the LCD to sit behind. One of the main objectives was to maintain the original look wherever possible.
Start by cutting down a sheet of perspex/acrylic to being just bigger than your CRT screen.
Position the CRT in a stable mount, luckily for me, my waste paper bin was just the right size to hold my CRT securely.
Lay down a scrap peice of wood or metal.
Using the hot air gun carefully heat up the entire surface evenly, the idea is to get it a point where it is flexible, but be careful not to over heat it as the perspex may bubble or deform.
How long this will take will depend on the thickness of the perspex, I had a sheet of 6mm so it took a while, in hindsight something closer to 3mm would have faired a lot better.
Once the perspex is cooked, carefully lay it on top of the CRT, the perspex will be hot, so be careful, wearing gloves will help. Hold the perspex till its cool, I used clamps to hold it to the CRT.
Next we want to trim down the excess, place the now curved perspex on top of the internal frame, mark the shape roughly with a sharpie (meths will remove any sharpie so do not worry if you slip into the view of the screen).
I drilled and cut most of the shape, I also used an unorthodox method of using an old soldering iron to remove and cut away some of the perspex.
The final screen should sit comfortably, but not wiggle around too much.
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