Any tips for mounting a TSOP34838 IR sensor in a 10mm panel? I'm concerned that just mounting it on the rear of the panel with a fairly small hole (4mm say) will make detection spread too narrow. Or is there an equivalent component that will project further through the panel?

Stick it on a scrap of wood. Keep drilling the hole bigger until the view is wide enough. Then ponder if you can tolerate such a hole in your final panel.
A note. Wood does not reflect. A smooth hole in an Aluminum panel will, some. So if the wood-hole seems marginal, find some Al and try it.
The clear rivet Jon suggests may zig-zag bounce the light, like a light-pipe or fiber optics. Or not, if the specific plastic does not carry IR well, or if there's notches and bumps where we need reflections.
A note. Wood does not reflect. A smooth hole in an Aluminum panel will, some. So if the wood-hole seems marginal, find some Al and try it.
The clear rivet Jon suggests may zig-zag bounce the light, like a light-pipe or fiber optics. Or not, if the specific plastic does not carry IR well, or if there's notches and bumps where we need reflections.
A friend of mine added remote volume control to a Carver C1 preamp. Instead of defacing the front control panel he used a remote mount IR sensor with a 3.5mm plug. The local cable TV company was using them for a while so there is quite a few to be found. He installed a jack on the back panel and the small black sensor can be mounted about 36" away. Now it can be aimed for optimum usability and hidden from view because of it's small size.
BillWojo
BillWojo
A friend of mine added remote volume control to a Carver C1 preamp. Instead of defacing the front control panel he used a remote mount IR sensor with a 3.5mm plug. The local cable TV company was using them for a while so there is quite a few to be found. He installed a jack on the back panel and the small black sensor can be mounted about 36" away. Now it can be aimed for optimum usability and hidden from view because of it's small size.
BillWojo
Good idea!
I think that's what's known as 'thinking outside of the box' 🙂
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