Printer is sending two new graphics. Both are backed by white ink and one has the transparent holes cut out for the starmap. If these are correct then I should have enough material to create 4 (two with holes and two without). I need to test bending the plastic around the existing starmap for those who want to keep it as it is and have a quick and easy install. I also took a look at what it would take to either replace the backboard with a new piece that has a routed out area or a cut out area or to modify your existing piece. It shouldn't be horrible, and personally I think I'm going to create a new backboard. It doesn't matter if it looks good or not, the plastic will cover the whole thing. I have a router, just need to get a bit, as I think I am going to recess the starmap for a completely finished look. I suppose I can make more of them for others who want to just replace. It's several screws and a few mechs to remove but should be fairly easy for anyone with basic skill.
The only question now is cutting out the plastic. I don't have a bandsaw or scroll saw so I was using my jigsaw which does an ok job but doesn't look like a professional cutout. I am guessing CNC cutting is going to cost a lot. I don't know what real plastics use to cut out, the backing looks burned so I was guessing a laser. Since you don't see the cutouts at all I was thinking that this isn't an issue.
I suppose if you want to weigh in, do you want to pay more and have it CNC cut or do you want to keep it cheaper and have it rough cut with a jigsaw?
Rough idea of cost of items.. depending on the plastic I use it's around $15-20 and the printed sheet is around $25-30 depending on speed of shipping, qty ordered, etc. So probably something like $60-70 depending on time and any other items I might need (blades, drills). I have a drill press so putting in the holes for screws is no problem. CNC cutting is probably going to add (just a huge spitball here) $50 to each piece given the low quantity I'm assuming I'll be producing. I can take a pic of the prototype with the rough cut I did so you can see it, if interested to know what it would look like. I really don't think it matters as long as no one is expecting a professional piece.