I've done a bit more work on the security pass insert.  I've started to hand paint the uprights (to his neck) which are not included on the decal.  Jeff from classic-arcades emailed me back early this morning and he is looking into the issue with the 250,000 decal and hopefully can sort it out.  There will be a small amount to hand paint on this one too, but thats AOK.  It would be great if this can be done, then all the fonts match etc..and less headaches.....If this cannot be solved, then plan B with some assistance from very kind peoples here we will give it a shot.  All mechanical bits and pieces now clean and ready to go.  Have 1 plastic to straighten.

I'm not too sure what to do with the lock down bar.  I was thinking chrome, but $$ and I don't want to pimp it out.  Just going for that clean look.  Perhaps just nifty clean, windex & sandpaper then buff?

Anyway, as soon as I've finished the touch ups on the insert will post more!