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Plexiglass for control panel -- cut it myself or have glass shop do it?
johnnysmitch:
--- Quote from: sofakng on July 14, 2004, 10:56:54 am ---Was I correct in ordering my plexiglass a little larger than my control panel?
Will I be able to trim the edge of the plexiglass to the edge of the control panel? (to make them both the same exact size)
--- End quote ---
Yeah, that sounds like a good plan there. Just make sure you do everything in order tho - you'll probably want to lay your plex on you CP (with your template/artwork/whatever in between), and drill a couple pilot holes through the plex where buttons/controls will be, and securely fasted the plex down with a few screws through these holes. You can then cut the plex flush to the CP with the router (might want to rough cut it fairly close first, so that you don't kill your router bit cutting away too much material - try not to cut with more than half the diameter of the bit at any time to keep it clean and smooth). Once the plex is cut flush to the CP, go ahead and cut the button holes out. leaving the ones with the screws holding the whole mess together for last (probably use clamps for those last holes). Good luck.
On a side note, to those who have used plex/lexan overlays, have you ever tried the heat trick on the edges? I've heard that using a heat gun, you can get the edges to 'melt' smooth, then even polish the edges up (with lexan I know you can even get a polished edge to carry light - ever see those exit signs with the glowing edges?)
fredster:
I drill thru the wood to size first. Then I put on the plexy and screw it down in several places.
After that, I take a 5/8 or 3/4 spade drill and carefully rough out the center. Then I drop a drimmel tool with a small sanding drum on it. It eats the plexi up. Keep circling it until it's the same size as the inside hole.
I never tried a router. I may do that next time, but I didn't have a bit like that either.
sofakng:
--- Quote from: johnnysmitch on July 14, 2004, 11:15:13 am ---Just make sure you do everything in order tho - you'll probably want to lay your plex on you CP (with your template/artwork/whatever in between
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I'm confused about why I would need my artwork in between the plexiglass and the mdf board?
I used my template to drill the holes in the mdf so if I clamp the plexiglass to the mdf, can't I just follow the button holes?
What I figured I'd do is this:
1. Sandwich plexiglass between junk mdf and my control panel mdf (with button holes already cutout).
2. Clamp everything together
3. Turn boards over so plexiglass is now at the bottom of my mdf board holes.
4. Use router to trim the edges of the plexiglass to make it the same size as mdf board.
5. Drill pilot holes into plexiglass.
6. Use router to trim/cut-out button holes from plexiglass.
7. Turn boards back over so plexiglass is on top.
8. Use countersink bit (in reverse) to countersink a LITTLE into four corners of the plexiglass.
9. Use drill bit (in reverse) to melt a hole through countersink spots.
10. Drill holes so I can screw the plexiglass to the mdf board.
I'm not sure why I would need my artwork if I did it the way I mentioned above.
Perhaps an alternative would be to clamp boards together, trim the edges so they are the same size, then countersink/drill screw holes to secure the plexiglass onto the wood.
Does that sound like a good way to do it? Any other suggestions about my plan?
johnnysmitch:
ah, i forgot that you have already drilled all your holes in your CP. In that case, then yeah, I think you've got a pretty good plan. Probably gonna want to drill/secure the plex to the board before you rout the outside edges though, so that you won't have clamps interfering with routing the outside (it's a pain to have to re-set the clamps so you can rout around them)
sofakng:
So would you suggest countersinking + drilling my four corner screws into my plexiglass onto my mdf?
These screws will permanately be there -- unless there is a better way to permanently secure the plexiglass to the mdf?