I have a 300 tdi Defender with the underdash full-width air con.

This makes it difficult to remove and replace the fuse box cover whenever it needs to be checked / fuses replaced etc.

Especially annoying is how difficult it is to relocate the 'knobs' which secure the fuse box cover back into the screw holes in the metal surround.

Has anybody come up with a solution for this ?

I am wondering whether I could fabricate up some modified fuse box cover. Would perspex be an option ? How easy or difficult is this to work with ? What about gluing pieces of it together to form a 3d shape ? And more to the point how expensive is it ? Do perspex places have "offcuts" bins ?

Any other ideas / solutions also gratefully accepted.