Helpful tips for box construction, t-molding, and plexiglass?

[J_Talbain]

Right now Im working on improving my homemade joystick (so it looks as l337 as some of the examples Ive seen from you people). The three main things I'm planning on doing are building a new box for the joystick (I'm most likely gonna copy the dimensions from someone else's project, most likely cdvision's panel dimensions), using t-molding (I'm not too sure about how to put this in but Ive seen it in other joysticks and it looks great), and printing out some artwork and putting plexiglass on top of the artwork. Does anyone here have some helpful tips? I'm looking for help specifically in the area of how to use plexiglass and t-molding. Also, what type of wood do you use and what kind of finish do you use? Thanks in advance.

[Sasquatch!]

You want to use a router to cut out the slot for the t-molding.  If you're like me and don't own one, borrowing one is good, because it sometimes even comes with the owner of the router who can help you!  I have yet to venture into the scary world of plexi, so I'm not much help there.

[Auntie MAME]

Use lexan in stead of plexiglass.  When drilling and cutting put a piece of lauan  over the lexan to protect it.

When putting in the t-molding you need to cut a piece off the back when going around corners.  By back I mean the part that goes in the slot.

[J_Talbain]

Well I don't plan on using lexan because everyone has told me that it is pretty expensive.  Also, any input on the degree of difficulty of using t-molding and plexiglass on arcade stick?  Thanks in advance.

[Auntie MAME]

A piece of lexan the size of a CP is about $10.  Lexan won't crack when you drill it.  I'm sure a number of people here have cracked plexi while drilling button holes.  I consider lexan an investment.  I only have to make it once.

[anthony691]

No one has mentioned that 1/4 in. plexi is half the price of Lexan. I found a better way than the score'n snap for cutting plexi, SPIRAL SAW! Plexi takes some aclamation, but once you get used to it it isn't so bad.