DIY MANUFACTURING GUIDE

Custom Panzer 4 Panels with SendCutSend.com

The Panzer Fight Stick 4 panel files are open source. This guide covers having your own panels cut through SendCutSend.com — and the one thing you must get right if you plan to add printed plexi artwork afterward.

Video Walkthrough

Jasen walks through the whole process, start to finish:

Watching directly on YouTube: Custom Panzer Panels On Your Own using SendCutSend.com

Get the Files & Convert AI to DXF

The machinable Panzer Fight Stick 4 panel files live on GitHub. Download the layout you want, or modify one to build your own.

Machinable Files · GitHub

PanzerFightStick4Panzer Fight Stick 4 Files→

SendCutSend takes DXF files. If you're starting from one of the .ai templates, convert it first:

1 · Open

Open the .ai file in Adobe Illustrator (Inkscape works too).

2 · Clean

Delete every layer that isn't cut geometry — artwork, guides, and annotations all need to go. What's left should be the panel outline and the holes, nothing else.

3 · Scale

Keep everything at 1:1 — do not resize or "fit" the geometry. SendCutSend cuts exactly what you upload.

4 · Export

Save/export as DXF and upload it to SendCutSend. Preview their render carefully — every hole should appear, and none extra.

Lever mounting pattern

Make sure your layout keeps the lever mounting hole pattern from the stock files. The hole positions in the Panzer 4 panel files are already correctly placed for standard lever baseplates — use them as your reference rather than laying out your own, and size the standoff holes to match the hardware below.

Hardware: Use M4 Standoffs

We recommend M4 standoffs for ease of use. At SendCutSend, that's the flush standoff SKU SO-M4-6 (M4 × 0.7 thread, .236" length, zinc plus clear chromate) — add them to the lever mounting holes when you order and the panel arrives with the hardware already pressed in.

Spec	Value
SKU	`SO-M4-6` (carbon steel · `SO4-M4-6` for stainless)
Thread	M4 × 0.7
Length	.236"
Hole size in sheet	.281" (+0.003"/−0.000")
Sheet thickness range	.050" – .111"
Min hole C/L to edge	.315"
Min C/L to C/L (same SKU)	.456"

Your DXF's standoff holes must be .281" for these to press in correctly — check the hole size before you upload. Full specs are in the video and in PEM's hardware catalog via SendCutSend's hardware page.

The 3D-Printed Spacer (Don't Skip It)

Why you need it

The standoffs available at SendCutSend aren't wide enough to support a lever baseplate on their own — the baseplate needs more contact area than the small standoff flange provides.

The fix is a 3D-printed spacer that sits between the standoffs and the lever baseplate, adding the surface area the baseplate needs to mount solidly. The video above shows the spacer and how it installs — print one before your panel arrives and the lever drops right in.

Artwork Templates: Read This First

Stock templates match OUR panels — not necessarily yours.

The artwork templates on this site are built to match panels as manufactured by Jasen's Customs. If your panel came from us, use them as-is.

If you had a panel cut by SendCutSend from your own design — or from a modified file — create your own artwork template from the exact file you submitted to SendCutSend. Your submitted file is the only source of truth for where your holes, edges, and mounting points actually are; a stock template may not line up with what you had cut.