Mercury arc rectifier

[ppppenguin]

I've done the perspex side panel. I drilled through all the fixing holes and bolted the metal panel to the perspex. I did most of the cutting with a 10tpi hand saw. This only failed when the amount to be cut went below about 1.5mm. Then I used a rasp, followed by coarse and fine abrasive paper. Even the rounded corners were OK that way. Several saw cuts plus rasp etc. Looks OK, especially as you can barely see the edges.

That panel was actually aluminium, but the front panel is steel. Now I need to find more perspex. I've got a big piece, about 4ft square, but I'd rather not cut into that for the 23" x 18" front panel.