Flush trim bit...hmm..

[ras2a]

Today I made a start on trimming the lexan for my CP...It turns out it's actually a sheet of Polycarbonate (bloody glass merchants...wait till I get my hands on em).  However isn't Polycarbonate, 'acrylic' and therefore more resilient to scratches/blemishes?

Anyway's I cut off the main pieces (angle cuts) using a ban-saw at work, then it came time to flush trimming around the entire circumference of the polycarb sheet.  I decided to use a hand-held makita router...simply because they're a lot easier to handle.  So I put the flush trim bit in and test trimmed on a scrap piece of polycarb.  Now it's either me or the 'bit'...but the bit seemed to be fairly inconsistent in the way it was removing plastic.  Do you think I would be better using a 'regular' sized router as they are much heavier and more powerful it may be a lot easier to do?

Anyway as I didn't have a lot of time today, I just opted to use a belt-sander around the entire edge of the polycarb to make it flush with the CP.  So, I clamped everything together, sanded ...and it turned out great!  But when I do the holes for the buttons/sticks etc later this week, I think I will opt for the larger router (more powerful)...what do you guys reckon?

Craig

[Grasshopper]

You'll be pleased to know that Polycarbonate is actually another name for Lexan.

Personally I prefer to use Acrylic (Plexiglass) bacause it is more scratch resistant, a lot cheaper, and easier to get hold of.

I trimmed the edges of my panel and the button holes with a

[ras2a]

Ahh thanks for clearing that up.  So I 'have' got lexan...cool, at least it 'should' be easier to cut.  All I have to do now (famous last workds), is to drill pilot holes and flush trim all my button/stick holes.  And then do the same with the trackball hole.  

I've heard of people using forstener bits to cut their holes in the ir lexan/plexi.  Are they easy enough to use?...which direction should you drill with them?

[FractalWalk]

If you have a router and a trim bit, then you don't need a forstener bit.

I routed my holes and the only issue I ran into is that my bit didn't cut quite quite flush with the wood and so my plexi holes were slightly smaller than the wood holes.

I think the issue was with my cheap bit, but a little sandpaper took care of the problem.

[ras2a]

If you have a router and a trim bit, then you don't need a forstener bit.

I routed my holes and the only issue I ran into is that my bit didn't cut quite quite flush with the wood and so my plexi holes were slightly smaller than the wood holes.

I think the issue was with my cheap bit, but a little sandpaper took care of the problem.

Yeah the bit that I got looks a bit 'cheapo'...but I guess it will do, after all it's only for one hole .  Think I'll use the bigger router on it too as it will offer much better balance and is miles more powerful so should make the job easier - less chance of 'dings' etc as it will (I assume) remove the material much more efficiently.

thanks