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How can I smooth the trackball plexiglass hole? (ouch! it's sharp)

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sofakng:

Last night I found my trackball mounting screws and attached the trackball.  I'm a little bummed and the trackball is below the plexiglass (it's flush to the top of the mdf though).  The problem is that the hole in the plexiglass is sharp.  It's not able to cut anybody but when you roll the trackball forward (or backward, whatever) you can feel the plexiglass hole and it kind of hurts.

Now I already have EVERYTHING mounted (buttons, joysticks, etc) so I'm not sure what I'll be able to do, but I was wondering if I should file the edges of the plexiglass hole with a metal file to make it smoother.... or perhaps use sandpaper (that causes TONS of scratches on the plexiglass surface though).

Any help would be GREATLY appriciated.

My cabinet will be almost complete after this!


CthulhuLuke:

I believe careful sanding w/ sandpaper should leave you without any visible scratches.  As long as you're careful to only have the sandpaper scrap against the inside of the hole, it should smooth out the edges.

Sylentwulf:

Someone in the past week had a GREAT shot of what to do with the plexi around the trackball. It involved routers and such, but the last part involved attaching something to a dremel to buff the plastic smooth...

ras2a:

or you could use a router and a 'bullnose' laminate cutting bit!..this will probably give you the best finish.  I haven't actually tried this myself yet but am going to do once I get my plexi/acrylic sheet

patrickl:


--- Quote from: Sylentwulf on August 10, 2004, 07:32:54 am ---Someone in the past week had a GREAT shot of what to do with the plexi around the trackball. It involved routers and such, but the last part involved attaching something to a dremel to buff the plastic smooth...

--- End quote ---
Yeah, that was in one of the previous threads you (sofakng) started about trackball mounting. You should go back to that previous question and read the suggestions there.

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