There are lots of great panel mounting systems out there to enclose your Replicator, but I wanted something a little different, so I came up with my own design. I bought a sheet of .093" (2.4mm) Lexan at Lowes to make side and front panels to enclose my Replicator 1. (I also made a hood from this lexan, which I'll post as a different thing.) Most of the other options didn't allow for the panels to fit flush in the openings, a feature I wanted in my design.

As I was cutting the Lexan I liked the look of the beveled corners on the Replicator and thought I could accentuate that feature with the brackets. For the top support I thought it would be cool to brand the bot a little bit, and came up with the round M coin to replicate the Makerbot logo. It's not exact (or official), but looks pretty awesome none the less. It uses the same back support tab as the side mounts to attach to the panel and can be printed single color or two toned with dual extrusion or by pausing and swapping colors.

Print 2 of the triangular mounts and 3 of the back support tabs for each side panel, as well as one of the M coins. (Files to print the M coin as one print and the separated files for dual extrusion are included.) I printed them at .27 layer height, 100% fill. You'll also need #4 (or M3) bolts and nuts to attach the panels. I used 3/4" long bolts with washers on either end, because it's what I had on hand. You should be able to use a 1/2" bolt, especially if you don't use washers.

For drilling the Lexan panels, I used the back support tab as a guide. Line the raised circular end in the corner of the Lexan (see picture) and drill an appropriate sized hole. Bolt the brackets to the panel then put into place in the opening. You can then turn the back support tabs outward to lock onto the wooden side walls. Tightened the bolts to secure.

The back mount tabs are designed to allow the Lexan panels to lie flush with the outer edge of the printer side walls to make it all flush and neat. Just be sure to accurately measure the lexan before you cut it. Just lay out your measurements, score the cut line with a sharp blade several times, turn it over, score the back side once or twice and snap the lexan apart. You may have to lightly sand the edge, but it comes out pretty clean.

Note: I currently have not printed the dual extrusion version of the M coin. The files should be correct, and as soon as I print one, I'll upload a picture. Also, these items were created with Autodesk 123D. I've included the 123d source files.

UPDATE The dualstrusion files "RepSideMlogo_M and RepSideMlogo_base" were not printing well for me. I've replaced those files with two versions. One lays the "M" on top of the base layer, while the other is two sided, the "M" flows through the entire print and is visible from both sides. Both versions still have the M and border raised on the front. I will post a flat version if anyone is interested..