Faceplate/chassis location

[gahult]

Hi,

I have started building an express (progressing well) and have to do the faceplate.
I find that with the 2" chassis + the bottom plate + the cork (or the sheet metal screw heads) the overall height is now 2 3/16th".
The chassis now contacts the back of the front panel and the center line for the holes would need to be adjusted accordingly to 1 3/16" from the bottom of the face plate.
Should not be a problem if I can manage to make the faceplate a tad thicker to make up for the difference in the set back from the front of the front panel.
On my next builds I may adjust the front panel for a bigger opening and make the face plate to 2 3/16th".
Anyone run into this?????
Any thoughts or solutions?

Thanks

Gary

[Allynmey]

Gary, make the faceplate opening 2-1/4" and make the faceplates 2". With the bottom plate on and weatherstripping (like the originals), you will be dead on.

[gahult]

Thanks Allyn.
I'll put it in my side notes for future builds.
That would make the front panel 5 3/8th's" and allow top and bottom clearance of 1/8th" for the 2" face plate.
For now I have to punt.

Gary

[gahult]

Oh,
And here is where I'm at on the build.

Gary