> a router on a small (e.g. 4"x6" box) piece of plastic isn't easy

Larry, I do cut-outs with a router and a 1/8" flute, following a template
made from 9mm mdf. The box is held by a jig, also 9mm mdf. It's not
so hard, although to do it that way, the tools to have are woodworking
ones (bandsaw, sander etc) to craft the mdf. The actual routing is the
quick bit. What I'll do next is to cut a piece of acrylic for the window
and route a lip on it so that it sits flush with the box. On top of all that is
a laminated label

Cases for current projects

http://home.clear.net.nz/pages/joecolquitt/cases_sm.jpg

Templates for the two different holes (16x2 alphanumeric and 4-digit)
and the acrylic insert

http://home.clear.net.nz/pages/joecolquitt/template_sm.jpg

This one was likely to get banged around so has extra acrylic

http://home.clear.net.nz/pages/joecolquitt/label3.jpg

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