I modified the dimensions to use 3mm Acrylic so it could be cheaper and faster to cut. I wanted to modify it so people could use hacker spaces and places like techshop laser cutters. Even at 40W you can still cut this in a single pass.
If you don't have access to a laser cutter let me know and we can work something out.
Revision E adjusted some spacing issues people noticed in the google group. I made the tube openings in the back a little wider and taller and corrected the hole spacing on the front panel. They were off by .5 mm.
It was suggested to use 10mm bolts for the hood instead of 12mm bolts by Shawn in the makerbot google group. I have updated the parts list below to reflect this. Thanks Shawn!
I recently updated the files to move the bolt hole for the right side panel to the top center instead of the sides. A few people noticed that on full size prints that the Y axis was hitting the bolt on the right side. If you have/made the older version you can remove the front bolt. It's plenty stable without it. This looks to be a problem with the orginal files so no matter what thickness you make you will need to move the holes.
I shorten up and modified the parts list to make it easier and included McMaster part #. Please note that I list how many pieces you need but the smallest packs are usually around 50 so you will have plenty of spares.
2 - M3 22mm Bolts (McMaster #91292A801 50 pack)
7 - M4 12mm Bolts (McMaster #90116A209 50 pack)
15 - #8 Washers (McMaster #90126A512 100 pack)
7 - M4 Nuts (McMaster #94150A335 50 pack)
15 - M3 10mm Bolts (McMaster #91290A115 100 pack)
15 - M3 Nuts (McMaster #98676A100 100 pack)
7 sheets at 20"x10" worth of acrylic at 3mm Thick
Step #1 Bolt the hood together with 12mm M3 bolts and set it on top. No Fasteners needed to hold it in place.
Step #2 Use the 12mm M4 bolts and washers to pinch fit the side panels on.
Step #3 Replace the 2 top front nuts/bolts with the 22mm M3 bolts to make a hanger to hold the front door on.
Largest piece is 19"x9" cut area.
(So any laser cutter that size or larger will work.)
60W Laser at 13mm speed at full power
(This was my laser cutter settings)