LOL "Press one to listen to some godawful music for the rest of your life... Press two to enter a further maze of menus from which there is no hope of escape... Press three to be abruptly disconnected... If you would like to speak to a human being, hang up and call one of our competitors who actually gives a s#@t!"
Had some overnight thoughts about this.
If I were gonna try this, I think I'd work in aluminum - it's easy to come by (you can get it from the K&S rack (http://www.ksmetals.com/) at any good sized hobby shop, and it's soft, but malleable, i.e., it will 'nibble' (more about that to come...) easily, but it will distort as you do it, and you can easily tap the distortion back into place. Brass would work too. A plexiglas piece would probably be cool looking, but plexiglas is a bitch to keep from scratching up, hard to polish once it IS scratched up, and cutting a square corner is nigh unto impossible...
If you decide to attempt this (and I would certainly encourage exhausting all options - beg and plead w/GB 'till they get sick of hearing from you - cause this won't be an easy fab - my guess 3-6 hours) contact me (or, if I'm not lurking around for a couple of days, email me at: bilbat@wi.rr.com), and I'll use digital measuring tools
to make you a dimensioned drawing to work from.
Buy two pieces of whatever stock you decide upon - you'll want to practice some of these techniques before you work on 'the good one' - there's no 'erasing'>
You will want a couple of tools. One is available at Radio Shack ($11) and is called a 'nibbler':
http://www.radioshack.com/product/index.jsp?productId=2289712
takes a little square nibble out of sheetmetal, bit at a time. You drill a hole in the center of your opening, big enough to admit the jaw, and 'work your way' out, then clean up the edges with riffling files (any regular hardware store - NOT a 'big box' store like Home Depot ("you wanna hammer? what's a hammer?? dunno if we got one of those...")
Other tool is a digital caliper:
http://www.harborfreight.com/cpi/ctaf/displayitem.taf?Itemnumber=47257
http://www.use-enco.com/CGI/INSRIT?PARTPG=INSRAR2&PMAKA=308-0197&PMPXNO=9398989
First you ink in your material with a permanent black magic marker (they make some stuff for machinists called 'DyKem' that brushes or sprays on, but marker works fine - and you can remove it at the end with some acetone)
then you 'set' your caliper to the required dimension by tightening the thumbscrew
and kind of drag one jaw along the edge, and the other jaw point on the inked surface to make a 'scribe line'
Good luck, and have fun!
Any questions or problems, feel free to post...
Bill