Best way to widen a buttonhole with plexi already installed?

[epac90]

So I got all of my buttons installed in my control panel no problem.  The very last thing I went to put in was the spinner (Ultimarc Spintrak).  It says that it is supposed to fit in a standard sized button hole, but the button hole is just not big enough.  I really don't wanna take everything off again, as I already have everything else installed. 

Can I just use some 80 grit sandpaper against the inside of the button hole??  I'm not worried about the mdf, I mainly just don't wanna hurt the plexi.  Will plain old sandpaper work fine on the plexi?

[Chris John Hunter]

 

[epac90]

Too thick?  It's only 1/8" plexi, seems like it would be easier to sand than the 5/8" mdf.  Well what the best way to go about some very slight removal?  I mean I barely need to remove any, probably within hundredths of an inches.  Also I don't really mind the plexi edges being rough, as it will be covered up by the knob (yeah yeah, that's what she said and all that good stuff... I'm trying my hardest not to make this whole topic sound perverted lol).

[chopperthedog]

The sand paper would work fine, but you may end up with unwanted dust under the plexi. I would shave the edge with a sharp xacto knife to remove necessary material.


good day.

[McHale]

[shponglefan]

Depending on how much material you need to remove, I'd just file it.

[epac90]

I thought about that also Chopper.  I'm thinking though if I can go in a downwards motions instead of going side to side, it may help that some.  Will definitely take alot longer, but atleast I wouldn't be working it into the crack between the wood and plexi. I also have the big silver knob for it so it will cover it up quite well.

McHale, Stepper bit would work great, and I know they work much better on plexi than other bits, but if that thing somehow grabbed the plexi or wood and my plexi got cracked I would be heartbroken.  I think I'll take the safe solution and just use some sandpaper.  Shouldn't take much at all with some medium grit paper and a little elbow grease.  I imagine the hardest part will be keeping the underside of the plexi clean.

[epac90]

Shponglefan, what kind of file should I use?  Like a round chainsaw file?   

[shponglefan]

Chainsaw file is probably too small.  I'd just use a regular half-round file. 

[Le Chuck]

Dremel with a drum sanding head.

[selfie]

Bad idea.

Dremel with a drum sanding head.

That is the only way I would consider doing it. Use the biggest drum sander that will fit in the hole. If you are limited by tool choice use the largest half round file that will fit in downward strokes only. You should be using a cross cut file, smooth or very smooth grade.

[lilshawn]

for as much f-in around as you'd do, trying to do it some other way, you might as well just disassemble the panel again and re drill the hole.

 

[Lilwolf]

You many want to remove the plexi, then mount it to another board.  Then drill with a bit with the center point, and edges raised (don't know the name, but most of my cheap, larger bits are like it).  And go slow and score it slowly.

Chance of messing up the plexi is pretty high.

[kahlid74]

Do it right, don't take the easy way out.  Take it apart and Dremel with a drum sander until it fits.  You'll be so much happier in the end.  Take it from a guy who has taken the easy way out before and regrets it every time.

[GoYouSalukis]

If the spinner has a substantial overlap that will hide the edge of the hole, I would use a half rounded file to enlarge the hole. It might be a good idea to use a sharpie around the edge of the hole so that you can see how much material you are removing.

[1500points]

i'd personally use the dremel, but if you are super concerned about dust.....use a soldering iron and work the hole to the size you want then trim the slag with an exacto.

soldering iron is a wonderful secret tool for working with plexi. 

[epac90]

Thanks guys, I used a half-round file and just took my time with it.  It got just a little dust around the inside of it, but not much.  Also, I have the big silver knob that they offer, either 1.5 or 2 inches and it covers what little dust got in under the plexi.  Just couldn't bring myself to disassemble it, as I am getting to the burnt out stage and am really wanting to finish it badly lol.  It came out good though.