How were the original Moog front panels made ? Each by hand? were they anodized or etch painted ? silk screen printed? Was there a standard aluminium thickness used ?
(I notice that Synth.Com panels are pretty chunky 1.5mm? The Moogs Ive handled seem more like 1.2mm.)
Has anyone tried a good home producing system? I would think anodizing is pretty straight forward?
AFAIK, they were etched using a very dangerous mixture, that is probably banned in 47 countries now.
http://www.synthesizers.com/moogpanels.txt
Bob:
On the old Moog modulars, were the panels sanded, clear anodized,
then silkscreened black with a reverse image?
Thanks,
Roger
Jan 13, 1998
Bob Moog Responds:
In 1964 and 1965 we made a few modules with ‘Metalfoto’ material.
Metalfoto is anodized aluminum with a photosensitive material embedded right
in the anodizing, and you ‘print’ the image exposing the material to
ultraviolet light and then immersing it in some photographic chemicals.
After that we used a meterial called 'Fotofoil" for modular panels. Fotofoil
is anodized aluminum in which the anodizing is dyed black and then covered
with a photosensitive resist. You expose the resist through a photographic
film, then wash away the unexposed portions. This leaves the unexposed
portions uncovered and the exposed portions covered by the resist. Then you
put the whole panel in lye, which etches away the uncovered portions and gives
you the panel design in in natural aluminum. That’s how all Moog modules were
made after 1965.
Bob Moog
As Voltor implied, it was a very dangerous process requiring personal protective equipment. And if I’m not mistaken, Kevin indicated that the process produces panels that were tough as nails…I believe he said that something along the lines of them being resistant to being cleaned with an acid.
Yes, a process such as this would produce an extremely durable finish. However, without knowing the chemicals used to make Fotofoil, I can safely say that just the lye (sodium hydroxide, for anyone who doesn’t know) makes it an extraordinarily toxic process. 
Toxic chemicals are fun!
EDIT- OMG, does this stuff sound fun!! 
Found an MSDS for it.
ammonium thiosulfatesodium thiosulfateboric acid, orthoboric acidacetic acid (sara iii)boric acid, orthoboric acidwater, h2o
Ozone depleting material indeed!
Very interesting process though, you can develop detailed photos in aluminum and other metals…like a Daguerreotype!
You can also etch your lungs and burn your nosehairs off while etching your corneas! 