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covering CP with plastic laminate
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djflip:
ok....i bought a sheet of Lucite to cover my CP, and i cracked it.  I don't know what i was thinking.  I have a perfectly good dremel i could have used, but i decided to try to snap it between my fingers along the score mark.  STUPID!!!!

Ok...before I invest on another piece of plastic to laminate my CP with (btw, the leftover of the sheet is going to be used for my monitor cover) is it possible to cut buttons out of it using a regular 1 1/8" spade drill bit?

please find my CP layout here : <a href="http://www.geocities.com/djflip_flop/controls/cp_layout_thumb.jpg">http://www.geocities.com/djflip_flop/controls/cp_layout_thumb.jpg</a>

I don't know if Lexan is stronger, and won't crack using a spade bit, but the Lucite cracked when i tried to drill a hole using the bit.  I tried drilling it directly into the Lucite, which cracked.  I then sandwiched the Lucite between two pieces of wood, and cut a hole that way.  Thta worked!  the hole was perfect.  Would this hold true for multiple holes drilled close together?
hyiu:
well.... my experience is... treat lexan like wood, and it will not crack.... very good although more $$....
FractalWalk:
Lexan is stronger than Lucite but if you drill it too quickly or without support (i.e. sandwiched between wood) it will crack.

I've never used a dremel on acrylic/polycarbonate but I would bet that it would melt it rather than cut it which would not leave a clean edge.

The best method is to use a router, but a drill will also work if you are careful.
dirt:
 If you run your drill in reverse you dont have to sandwich the lucite. It will melt right thru it no problem with no cracking.


dirt
REBIRTH:
I used Lexan and drilled holes in it just as I would have drilled a hole in wood, with no problems at all.  I did sandwich it with wood for more support, but I ran the drill pretty fast without problems - no reason you can't goslow to make sure though.  What I did was:

(1) Cut the holes out in the CP first (I used wood, should be the same with MDF

(2) Placed a full sheet of scrap wood on the bottom, then the Lexan on top of the full sheet of scrap wood, then the CP with the holes on it on top of both of those - all clamped together so they were like 1 sturdy block.

(3) Put the drill bit in through the CP button holes into the Lexan and drilled away.

Here is a picture...
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