After making the Aluminum Xbox Series X and creating a back panel transparent green, we set out to create a back panel that would work with the stock case. There were many positive comments about it!
This was an easier project compared to the prior and what I have planned for the future. Making something that adds a really unique look is definitely worth it though! The Amber back panel is straight fire.
To achieve make these we had to forgo the clipping mechanism. We retained the top lip for stability and the two screw holes towards the middle/bottom. Due to keeping the lip, we CNC machined the entire panel compared to the previous panel where I just laser cut it on the K40. Doing it this way made a nicer panel with no warpage too!
The panels are made out 3/32″ acrylic. To hold the material so they could be machined required making a jig. I had a leftover piece of 1/2 MDF that I had used to make the bed for my Pick and Place machine. With a little cutting and machining it was a workable fit for machining soft plastic. It has 8 holes: 4 for mounting straight to the bed and another 4 for holding the aluminum brackets that clamp on to the acrylic (they also mount to the bed). There is a pocket for the material to slide into. Believe it or not there’s only about 0.010″ difference across the 18 inches of the MDF jig. Pretty good.
Machining the panels was done with a single tool: 3 flute 1/8 in Carbide End Mill. The CAM program first does all the slots and holes then the engraving and lip profile. Last it cuts out the piece leaving a few tabs to keep it in place. The tabs took a little experimentation as they were either too short or too big. Too small and they don’t machine well if at all, and too big damages the panel when breaking off. We finally got it dialed in towards the last panel. Two panels can fit on a single 12×12 sheet with not much wiggle room.
We cut four colors: Amber, Blue, Clear, and Green. Amber is my favorite, followed be green. The blue is very light; I expected darker more in line with the green. Blue still looks great, in fact, they all do. Which color do you like?
Since I had the program and jig all made, I made a few extra panels you can buy here. Installation is easy: remove screw sticker/covers over the two screws, lightly pry to pop out the rear panel, and put the new panel in. Reuse the same screws you took out.
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I love creating and building things. I have been doing Mechanical Design and CAM programming for 8 years. I also love Gaming, Electronics and PCB Design.