Oldfast,
No real problem with alignment on this one due to the Lexan. Cut them to size, then taped the edges exactly together, then drilled a very small hole where the center of the spindle would go. Removed the tape and separated the pieces. Used a spade bit to cut the spindle hole, a little from each side of each piece to keep the edges from splitting.
Taped the lock in place and used an awl to mark the center of the screw holes, and drilled using a very small bit (yes, hand powered drill for the fun of using it), and gradually larger bits until I had the screw holes the right size. Too large a bit, and it will split and crack the Lexan. Luckily I practiced on a scrap piece of Lexan, or I would have messed up the larger pieces!
Then I put the plastic into the channels of the frame with the lock attached to the rear panel. Set the dial ring in place and installed the dial into the cam. Rested the frame on the back and aligned the dial ring as close to center as I could on the front panel using the dial as a guide. Taped the dial ring in place and removed the dial, then the panels from the frame. Marked the holes for the dial ring, drilled and wiped up the dust and debris. And wiped it again. Then used air from my compressor. And wiped more. And more air. For those who didn't know, Lexan seems to generate a static field that will draw every piece of dust or lint for a 14 mile radius. As I live in the desert, that is a considerable amount of dust!
But that covers the alignment. Again, made easier by stacking the Lexan panels on top of each other and drilling a center hole.
Gordon
Just when you think you've learned it all, that is when you find you haven't learned anything yet.