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Plexi-glass frustrations :( More delays

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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?

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