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Extruded vs Cast Acrylic Plexiglass
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AzureKnight:

I have to admit that I am more of a software guy than a carpentry guy.  I've worked with hardboard a few times in the past and found it a total nightmare to try to get a clean cut on.  If I did go that route any recommendations?
PL1:

--- Quote from: AzureKnight on July 11, 2014, 10:52:28 am ---I have to admit that I am more of a software guy than a carpentry guy.  I've worked with hardboard a few times in the past and found it a total nightmare to try to get a clean cut on.  If I did go that route any recommendations?

--- End quote ---
A drill guide is your friend for drilling vertical holes using a forstner bit/holesaw.

Having a spoiler board behind the material you are drilling thru will help you avoid blowouts.

Here are several approaches to building a layered panel:
(Use a scrap of hardboard to verify if your forstner bit/holesaw makes a clean hole before trying METHOD 2)

METHOD 1
1. After you cut the 5/8" MDF base to the desired size/shape, cut a slightly larger piece of hardboard.

2. Drill the button holes and the round joystick holes in the MDF with a forstner bit/holesaw.

3. Clamp the MDF and hardboard together.

4. Drill holes in the hardboard large enough to fit a router flush-trim bit.

5. Use the flush-trim bit to enlarge all the button holes and round joystick holes to match the MDF.

6. Use several buttons in the farthest-apart holes (minimizes wiggle) to hold the MDF and hardboard together.

7. Trim the outside edge of the hardboard to size using the flush-trim bit.

8. Route/drill the pockets for the joysticks in the MDF.

METHOD 2
1. After you cut the 5/8" MDF base to the desired size/shape, cut a slightly larger piece of hardboard.

2. Clamp the MDF and hardboard together.

3. Drill the button holes and the round joystick holes with a forstner bit/holesaw.

4. Trim the outside edge of the hardboard to size using the flush-trim bit.

5. Route/drill the pockets for the joysticks in the MDF.


Scott
SavannahLion:

--- Quote from: RandyT on July 10, 2014, 04:35:47 pm ---Here is a nice page which points out the differences.

For a cabinet window, cast would be better for the scratch resistance.  Probably the same for a CP (sorry didn't see that part originally).  If you go with extruded, and have it laser cut, be careful about using solvents like alcohol for cleaning.  It can have some bad effects.  Better to avoid solvents altogether with laser cut or flame polished parts, just to be safe.

--- End quote ---

Holy crap... I had no idea extruded has such variance.... the core layers in my project are made using Acrylic sheets. I better check those measurements before I put it together....
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