In case anyone can use parts of my homemade protector building technique for EM games. I wanted a playfield protector for a game nobody makes them for (1967 William's Apollo). I got it done and am very happy with the results. 1st step was ordering 0.02" petg sheets from Walmart. This is the same material the German playfield protector place currently uses. https://www.walmart.com/ip/3-Pack-PETG-CLEAR-PLASTIC-SHEET-020-24-X-48/911517885. Lightly clamp it to the topside of glass so you can trace the plastics edges without it shifting(this works for older EM games where glass is close to the plastics)

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Then trace the plastics using 1/8" extra space so the protector can thermally expand without bumping into posts and warping. Use wet erase markers so marks arent accidentally wiped, but you can erase and redo if you made a mistake. Of course do it all with the protective film still on.

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Now cut out the outside perimeter/plastics so you can put the protector right on the playfield and match mark the lower playfield features more accurately than you could have done from a few inches above. Remove whatever is necessary flippers and pop bumpers at minimum using your judgement.

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Now mark the lower playfield-level feature cutouts. Then cut them out (away from the playfield of course). I found that fine tooth drill hole saws worked best for perfect circles freehand. Use scrap wood underneath the protector when drilling. Spade bits dig too fast by hand, but if you are using a press then maybe they work. Standard bits can be a good way to start an interior cut and then you can finish with scissors.

Now double check all cuts, fine tune as necessary, and you're done! For rollover buttons I make discs from the playfield material using a punch set and a bench clamp to press the discs out. Then glue the discs to the top of buttons. This allows the button to match playfield height as the ball rolls over and eliminates need to adjust buttons further just because you added a protector. Wont be perfect because the buttons never were in the 1st place! I also lightly wax the playfield before installation and the top of the protector after. I use scotch tape to anchor 2 spots near the top arch to keep the protector from shifting. No more than that or you might get warpage with temperature changes or as the playfield insert lights heat up.

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For newer SS games where the glass is not right over the plastics, you may need to remove glass and rest the protector on top of plastics to match mark. If it flexes by it's own weight you would need spacers to prop it up level I guess. Should still be do-able!

Yep I wanted to avoid the "paper route" and match-mark everything instead