Since the plexiglass is now glued to the front of the MDF template I was able to cut it to final size using my flush cutting bit and my router. The ball bearing on the bottom rides along the edges of the panel and the bit cuts through the plexiglass like butter. Here is a shot of how it works:
I had a harder time than I thought I would setting everything up and I had to switch bits in my router to cut out the interior areas (I tried starting with a drill bit and I chipped the plexi and almost had a heart attack!).The front panel is looking pretty good now - the lines are clean and everything is symmetrical. The rounded corners are a nice touch too, IMO.
The next step is to repeat this process using a chamfering bit to put a 45 degree bevel on the edge. Too bad I can't remove the protective sticker until construction is finished - I'm anxious to see what it looks like!
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