🚀 go-pugleaf

I'm trying to make a nice-looking aluminum front panel for a project,
and I'd like to be able to use rectangular switches, possibly other
squared-off displays, etc.  How do you cut a perfectly-squared-off hole
in an aluminum panel?  Is there some home-brew method I'm not aware of?

Also, what's a good way to do the lettering?  I've got a LaserJet, but
how do you transfer what's on paper to what's on the panel?  

Recently, I heard about a method of PCB manufacture whereby you print
your PCB design to some special type of paper, iron it on a copper-clad
board, and then etch as usual.  Seems to me there might be something
similar for lettering.  That way, you could lay the entire thing out on
a Laser printer, iron it on, and then maybe seal it with some kind of
polymer-based sealant...

-David Victor