Did lots of drawings - and trips to Kmart to measure the thickness of nylon cutting boards - then started making up the electrical distribution bus bars. I will mount them behind the panel (on the back of the panel) so the wiring from the bus bars to the circuit breakers to the switches is all on the back of the panel.
Cut 2 thickness cutting boards (1/2" and 1/4") and then measured the spacing and drilled the holes in the copper bar.
Located the bus bar position on the panel and drilled mounting bolt holes. Will have to source some countersunk machine screws to go onto the panel so they don't protrude. The panel will be a doubler - alloy backing plate with coloured plastic sheet of some kind as a feature cover plate. Circuit breakers and switches will have their own face plates (easy to correct or update!).
1/2' nulon cutting board.
1/16 x 1/4 copper bar.
Punching, and then drilling, the firewall to take the bus bars.
