how to add plastic panel over aluminium?
A few years ago I built a Lilliput into my BMW's dash. The screen is bolted to an aluminium plate, like so:
You can see the small holes at the top of the plate; this is where it screws to the mounts that are part of the dashboard itself.
Then I had a flat piece of ABS plastic (from a Playstation) laid over the top:
This piece was cut just a little too big, so that the pressure on each side held it in place. It was also gripped by the buttons on the left side, which are a push-fit type.
Trouble is, after four years that plastic is properly ruined and the aluminium plate buckled and bent from being taken out and reinstalled so many times. I'll be making a new aluminium plate, but I can't think of a good way to secure the plastic over the top. The plastic needs to be removable as it covers the aluminium bolts, so glue is out of the question, and it needs to be held on tight so that it doesn't buzz or rattle when driving. If I use something like velcro pads the plastic will be pushed too far away from the aluminium and there'll be really ugly gaps. So I'm a bit stumped for ideas.