[Nathan Slingerland]

So what's my plan here?

I scanned in the trace, cleaned it up in Photoshop and Illustrator, and created the attached document.

Philco 29CSX Cover.pdf Size: 58.32 KB  Downloads: 172

I printed out the design on 'tabloid' (11" x 17" paper) and mounted it on cardboard.

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Being someone who is (much) better with computers than woodworking my initial thought was to use a laser-cutting service like Ponoko to make a perfect replica of a printed design. Unfortunately laser cutting isn't available for a material as thick as the original. Steve noted his panel is 3/8" thick.

For comparison purposes - and because the top panel also needs to be refinished I removed it and measured it to be close to (but slightly under) 3/8" as well.

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Fortunately it so happens that a friend at work enjoys building finely crafted computer keyboards out of wood. In fact, he has his own computer controlled router setup (not the computer kind of router but the wood working kind). Those are able to handle much thicker material - and my friend generously offered to help.

All I needed next was the material to cut. Initially (before I had taken the cabinet apart) I thought I was looking for was 3/8" thick walnut plywood. This is an unusual thickness so it took some Internet searching I found it at Owyn's Lumber. I placed an order - but when I finally received it it came with a very nice letter from the owner:

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Talk about customer service! They sent me two pieces - 1/4" thick walnut plywood - but also 3/8" cherry plywood.

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In fact, after looking more closely at the top panel (should've taken that off before ordering!) I don't actually think it's walnut at all. It's just using opaque toner to blend with the other parts of the set. The cherry should work just fine and be the right thickness.