Plexi-glass frustrations :( More delays

[Demon-Seed]

HI
I have been trying to get my control panels plexi glass cut and fitting just right. I hvae wrecked three 20 dollar pieces so far..each time I almost get done and then cracks somewhere. Yesterday my dad did onfor (so No 4) and it worked great no cracks..nothing. I sat it down did some work went back to it and found a three inch crack in it! err I have no luck. The crack is int he center where the track ball goes. I know i have the steel square bracket that goes over top of the trackball cut out but there is still roughly a two inch crack showing. I do not want to buy another piece or ask my father to assist again. I have spent too much money, time and aggravation on this piece of plastic.  I am trying to think how I can fix or hide the crack. I was thinking of just cutting a small piece of black plastic but may look wierd any suggestions!! The crack is located directly above the trackball. please provide advise?? I need to start my wiring and this is holding me up. I would appreciate anyone's hlp with a resolution.

thx
JIM

[Grasshopper]

I can't offer a solution for hiding your crack. However I'd strongly recommend you invest in a Router ( I'm assuming you didn't use one, please disregard my comments if you did). In the long run you won't regret it. Cutting plexiglass using a router fitted with a laminate trimming bit is incredibly easy. It look me about 10 mins and I had no woodworking experience. You can cut the button/joystick holes and trim the edge of the plexiglass at the same time. You simply use the wood as a template.

A cheap router + a few bits could be bought for less that the $60 you have wasted on plexiglass so far.

Before I got into this hobby I though woodwork/metalwork etc required a lot of skill. I now realise it's 90% about using the right tools for the job.

[Demon-Seed]

Hi
Thanks for the tip third go we used a router worked great it was fine.. but my dad left the plexi glass paper on it and when I pulled it off the control panel it cracked.. i am going to get another piece and give it another go

[Zakk]

How thin a piece are you using?  Maybe a bit more thickness to the plexi will take care of the cracking (at least when taking off the protective coating.  
 I cracked almost every piece of plexi I did, for every cabinet, at least once, until I followed Oscar's advice and started using a router, which took care of all the cracking problems.  However, don't try and rout it with the protective cover off, as it will leave a lot of scratches. (can you tell I have -no- luck with plexi?  

[patrickl]

Why not use Lexan instead?

[SteveJ34]

Why not use Lexan instead?

I second this idea. I used Lexan for cp, marquee and front "glass" cover.

I had no problem drilling this out for buttons and trackball.

[rdagger]

I agree on the Lexan.  The money wasted on the cracked plexi would of covered the extra cost of the Lexan.  I've had very good luck with a router for holes and a sharp box cutter for cuts.  For complex cuts, I've used a handheld jigsaw.   The only way I've been able to ruin Lexan is with a chop saw.

[Zakk]

The local HD tripled the price of lexan vs plexi here.  Pretty much the only reason I gave up on it...

[menace]

Whats your current method of cutting?  for size cutting I used an exacto knife, made a bunch of very deep scores and it cracked very nicely along the score(as well as severing that useless end of my thumb I never use ) for holes, I sandwiched the plexi between two scraps of plywood, clamped them tight and drilled the holes with a hole saw from crappy tire--not one crack for three CP's and 3 "backsplashes" in one session.  I think it was 1/8" or 3/16" stuff bought from HD.

[Demon-Seed]

I got a new piece dad used router np!

[Jakobud]

Why don't you just buy lexan? It won't crack.  People complain about Lexan cause it's too expensive, but if you waste three $20 pieces of plexi in the process, you've already far surpassed the price of lexan.

[Safron]

I thought Lexan scratched very easily.
Wouldn't that make your CP look kind of rough over time?

[patrickl]

Plexi scratches too. I don;t think there is that much difference in it.

Maybe a bit too late, but isn't the easiest option to buy a laminated CP overlay? I was going for CP with a printed CPO covered by a sheet of Lexan myself, but since I have seen how happy others were with the printed CPO's I'll go that route instead. I made a self laminated print and even that looks pretty good. Drilling holes in a wood panel is a lot easier and you won't have so much trouble with scratches. I think it looks better and it won't matter much in costs either.

[Rawker]

you got a new piece, but if you haden't i would have suggested getting some sort of vinyl decal to cover it.

[Jakobud]

Yes Lexan scratches slighty easier than plexi, but unless you are digging your fingernails into it while playing you really have nothing to worry about.

[hulkster]

well heres another alternative.....i cant remember who used this first so sorry if i steal your thunder....but anyway, if you are getting cp art, just get mamemarquees.com do it in an adhesive vinyl.  that way, it wont scratch, and you wont have to worry about cutting plexi or anything.