Summary

Simple to make cover and windows for the Makerbot replicator. No laser cut parts. It's made from about $30 of 2.5mm (.1") acrylic, printed parts, and only needs 6 #1x3/8 screws and glue to put together. The top is supported around it's entire peremiter so it's very sturdy but also light.

Instructions

Parts list:
2.5mm (.1") Acrylic (Amount depends on how high you make the top, I used about 1 and a third 3'x2' sheets)
6 #1x3/8" Servo mounting screws (They have built in washers)
Small bottle of ABS/PVC cement. Oatey #30818 or other.

Printed Parts:
Window Centering Tabs - 6pcs
Window Clamps Bottom - 6pcs
Window Clamps Top - 6pcs
Window Joiners - As needed
Back Window Joiners - As needed
BackTop Window Joiner - As needed

All parts were printed with a .2mm layer height and 100% infill.
If you are using the OpenSCAD files the dimensions.scad file must be in the same directory with other files. If you want to change the acrylic thickness it's in that file.

Window Instructions:

Cut the acrylic for the windows about 1/8" biger than the openings all around.
Glue two 'Window Clamps Bottom' onto the inside bottom of the side windows about 1/8" up from the bottom and 1" from the sides. The tab should extend about 1/16" below the window. Glue two bottom clamps to the front window 1.75" from the sides.
On the side windows drill 1/4" holes for the 'Window Clamps Top' about 2" in from the sides. You will have to adjust the posistion of the back clamp on the right hand window to avoid interference with the cables. I just left that one off. On the front window make them about 2.5" in from the sides.

Drill out the holes on the outside clamp halfs (the ones with the hole al the way thru) to clear the screws. Drill the hole on the inside half to fit the screw if needed.

Assemble the clamp halfs onto the windows. Adjust the friction fit of the clamps by tighting the screw as needed.

Put the windows in place, turn the clamps up to hold them in. Center the windows in the openings and then glue a centering tab onto each bottom corner while holding the window in place. They will keep the windows from sliding around.

Top Instructions:

Cut the pieces for the top a bit oversize and then trim them to fit with the joiners on them. I made mine about 6.75" high, but you can go a bit closer to the cables if you want. I wanted to leave room for when I changed the filiament. The top should fit sungly into the top recess of the Replicator. Leave about a 4" gap in the back for the cables. It helps to sand the edgss a bit so the joiners go on easier.
Miter the joiners on the top corners and then but the corner joiners up under them.
The wide joiners for the back can be trimmed to fit into each other.
Test fit all the top pieces together before gluing them.
Once everything fits OK glue the joiners to the acrylic.

DIY Replicator Cover and Windows