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Lots of things were giving me the shits at this stage, so morale was low. Initially I did most of the shaping by hand as every time I tried to use the sanding drum on the Dremel it would tear apart. I think I realised later that I had the RPM too high and the centrifugal forces were splitting the sandpaper drum apart. Once I got the hang of shaping with the Dremel, life seemed brighter.

I decided not to bore you with the 50 thousand 'in-progress' pics of the shaping process. Note, there were several applications of body filler and subsequent shaping before I got to the following stage.

Obviously this is less than perfect, but given the time restraints and the fact that this will not actually be visible, I didn't bother filling and sanding any further. If it was external or visible, I wouldn't have tried to make it perfect.

After measuring and marking up the required cut out for the little front panel LCD and cables, I cut it out with the Dremel.

Quick check. Fits roughly.

 More reinforcing and shaping work was required.

Some famous 'Spray Putty'. I've never used this stuff before either.

By the way, I have a 'Multi-tool' (disc sander/linisher) attachment on my bench grinder which I used to sand down the edges to give the correct external dimensions.

Another trial fit and I start to see where I need to make modifications to the front panel.

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