So why do I need a version 3? Version 2, takes forever to print and the printers are in the library (still closed). So that leaves me to go look for a better solution.
Along comes The Container Store. They have an acrylic box (Kid's Shoe Box, clear and ventilated. UPC: 01-10048429-1, They are made by Nam Ngai Hong #605) with a Size (cm.):15.5 x 21.5 x 7.6. This comes without any protective covering (tape of sorts). So use blue painter's tape for you to mark up lines. 
Now the problem with acrylic is not easy to play with. It cracks, chips, etc. So let us get down to the solution.
Cobalt Drills with a 60˚ kerf are recommended but they are really hard to find and very expensive so, I'm using Milwaukee Shockwave Titanium Bits with a Quad Edge Tip that works really well, they have a very small tip see image on the left. It cuts like a dream but be sure to use a waste board under the work, and yes clamps.
For bigger holes well then you have to use a Milwaukee Hole Dozer, and use a 1/4" pilot hole. For ease, I usually start with about a 1/8" bit followed by the 1/4" bit. Next I chuck up the hole saw and use the 1/4" hole as a guide. Not a lot of pressure and maybe some Dawn soap on the cutter.
For shapes, you have problems again. Some Dremel tools will work, but for larger holes start with your 1/8" drill then go to a 1/4" bit at which time you can use a 1/4" Cobalt Rotary Bur. Or you can try a Rotozip bit but use it on a high speed.
As there will be continuing alignment problems, I have decided to make three (3) jigs from plywood, one for the front and the back (long sides) and also for mount boards in the base of the unit. This will allow me to align the Arduino Mega PCB in the bottom and the hole in the long side for the USB connector. I also need two (2) RJ-45s for my communications network (not ethernet) for the radios, but RS-485 using the NASA EADIN Light protocol which will be converted to CANaerospace over IP.
