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Very similar to the routers mentioned above I'd suggest a used Hitachi TR12, they're like the old Toyota hilux of routers.

400437

Approx 8mm Perspex from Bunnings
Sheet cost about $60 from memory but enough meat to make at least 2 inserts.

If I was to make another I'd use melamine and spend big on a router lift if...

I haven't used this myself but heard its fairly quick/easy

http://www.squarespace.com/


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I'm definitely not an expert but I'd drill a few mm deep and apply something black then coat with clear poly.

I recently used cabots oil based clear poly to fill a large size knot hole on this...