I haven’t got any photo’s inside but here’s a snip of the CAD:
The steps I used were:
- Face 0.25mm deep
- 2D countour to get the overall outside shape
- 2D pocket to create the inner
- 2D pocket to create the through hole inside
- 3D horizontal to reduce the height of the faces where the numbers are. (I struggled with picking a good process for this and the paths were’t great.)
- 2D bore to create the holes
- 3D ramp to rough out the curved part of the spigots around the numbers
- 3D parallel to create the curved faces (isolated to that area by picking faces)
- Engrave with a 20º bit.
- Mount in lathe, face of material on back
- Mount in mill to drill cable holes.
Steps 1-5 = 6mm 3 flute end mill, mostly 0.5mm DOC, ~1000mm speed and ~3 on the router. 6 and 7 were 3mm single flute @ 0.25 pitch and 0.25 step down ~500mm travel. 8 was a 6mm ball end. Work holding was superglue and masking tape.
It took me a 3D printed prototype, plus four tries to get to this point (2x Delrin, 2x aluminium) and probably 16 hours between the program and the machine, but to be honest I could thrash it out in WAY less now. Steep but rewarding learning curve!
I look forward to seeing what you make for yours!