Hole in lexan for TB?

[ThePaul]

Hi and thanks for taking time to read my question.

I have my TB mounted using a mounting plate. Everything looks good, but I still need to add the artwork and lexan. My question is.. how do you guys get the TB hole lined up to drill through the lexan?

Also do you just cut a 3" diameter hole in the lexan even the the part of the TB that actually sticks out through it is smaller than that?

[Jakobud]

Router.  Use the mounting plate as a guide.

[chrisindfw]

Here is what I did. It is kind of ghetto but it worked and saved me from working with the router.

First I took a scrap piece of wood and drilled a hole at one end.

On the other end, I screwed a screw into it with the point sticking through the bottom of the wood where the edge of the hole would be.

Then I drilled a hole in the middle of the tb area.

I attached the piece of wood with a small nut and bolt and made it tight enough so the screw made contact with my lexan but loose enough so I can spin it.

Then I began to spin the wood. It didnt take as long as I thought. Be patient and go the same direction every time.

Once I got going, I moved it to the other side of the lexan and tacked it from that side.

The result.. A smooth hole with no nicks. And it only took me once to do it. I tried other ways but kept messing up my lexan.