Next I installed the front enclosure component. This component has pockets cut that will hold the power switch, Probe Jack, and Estop Switch.
In order to gain access to the inside of the enclosure, we wont be installing the clear panel at this time.
Attach Front Enclosure Component
Secure the front enclosure component as you did the rear by securing with two #6-32 x 3/4" machine screws, lock washers, and hex nuts.
Attach Power Switch
Remove all the hardware from the power switch and insert it through the hole from the inside of the enclosure.
Add the plate, washer and nut and tighten.
Prep the Terminal Block
All inputs share a common ground. To accommodate this I installed a terminal block with a buss bar installed.
Install the buss and a single hookup wire to attach the common terminal on the controller.
Not that you can also go with an old school terminal block and just run a wire through all the terminals on one side of the block.
The new style terminal blocks can be found on this page:
Install Terminal Block
Position the block, mark, and drill the mounting holes with a 3/16" drill bit.
For the newer termianl blocks secure with two #6-32 x 3/4" machine screws.
For the old school, use two #6-32 x 1" machine screws.
Attach Ground Wire
The ground wire should be attached to the input block marked GND or COM. Some controllers require you to solder to a DSub connector.
For the G540, the wire should be connected to position 12 on the terminal block.