Step 2: Front panel
Designed an overlay in Omnigraffle on a MAC, printed on to overhead projector film with a laserjet, there's an inkjet equivalent. Chiseled out a channel for the overlay so it had a nice inset look.
I fell in love with a power switch from a piece of development hardware at work, unfortunately it was a momentary switch so I spent quite a lot of time retro fitting a N/O microswitch with a blue LED glued to the tip.
The edge of the large front panel section was routered.