I have some safety covers intended for a round switch that I hope to use on this panel. My switches are square, so I'm going to try filling in the cover then making a new, square hole.
This is a short strip of 5mm thick ABS which I'm going to use to fill the existing hole.
Machining the strip to match the width of the hole.
I sawed out two parts about the right size, and I can clamp them both at once and make them the same length too.
A quick digression to show what might become the new dust/chip collection system. This is a long, thin, flexible attachment from a vacuum cleaner spares shop.
It's a good size for getting up close to the cutting tool and still providing a decent amount of suction.
The nearly finished blocks of ABS are a sliding fit in one dimension but need reduced slightly in the other.
I wish I'd bought this micrometer stand years ago. It so much easier to measure small parts.
A bit of sanding made the blocks a good fit in the hole. I've also roughened the top and bottom faces to help the adhesive bond.
This epoxy was bought for another low-volume project and gets hauled out for everything I do since.
