>> http://retrocmp.com/projects/pdp-11-70-panel-on-blinkenbone/243-simulated-pdp-11-70-panel-on-simh

That's a work of art, together with the PDP-10 he did. I saw them running on a 
nice touch screen at VCF Berlin, and I wondered whether all this physical 
replication stuff makes sense when that's around at zero cost. Then I put my 
blinkers back on and went ahead anyway :)

>> You hit upon one of the key needs for these projects, a good replica bezel. 
>> In my project I had to have a plexiglass bezel laser cut then used white 
>> plastic 
>> to frame that bezel. It works but I would love to have a replica bezel.

Did you perchance make a CAD design for that, which could be reused? ;) I'm 
drafting a design at the moment, but far from perfect still.

I think of all the technologies available for making the bezel, vacuum forming 
seems to make the most sense. Injection molding is much better quality but just 
too expensive (tens of thousands USD). The other approaches, I think, work fine 
for small quantities. But I suspect there's a 'need' to make a few hundred.

Probably the best way is to make a very good open-source CAD model. Then make a 
low-cost vacuum forming mold, whilst anyone could still use the CAD file for 
higher-quality one-offs on a CNC router or, perhaps, 3D printer. The problem 
with vacuum forming is that you cannot make much more details other than the 
outer hull, which will look fine but need a lot of work on the inside to really 
mount in an original PDP-11.

Regards, Oscar.
                                          

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