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Author Topic: Cutting trackball hole in plexiglass (revisited)  (Read 16657 times)

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ras2a

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Re:Cutting trackball hole in plexiglass (revisited)
« Reply #40 on: November 17, 2004, 11:53:21 am »
Definitely don't try to use the trackball mounting plate as a guide for a flush bit on a router...I made the mistake and had to buy a second mounting plate.  Even if the mounting plate is made out of metal, even an old router can rip right through it.  I ended up using my old (read ruined) mounting plate as a guide to create a new template.

If the hole in the centre of the trackball plate is 3", I can just go ahead and create a MDF template with my 3" hole-saw right?.  I can then fix this to the bottom of the plate (somehow) and use the extra depth for the flush trim bit bearing to ride against whilst cutting the hole in the lexan.... Is that hole EXACTLY 3" though....me measure when I get in from work!

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Re:Cutting trackball hole in plexiglass (revisited)
« Reply #41 on: November 17, 2004, 12:54:10 pm »
The way I see it, if the router bit is tight within the router and a steady-hand used, then there can be no movement up and down and therefore no chance for the router bit to 'dig in' and ruin the trackball plate.  Does this approach look ok and is this the method used by some other people?

As long as the bearing on your bit is right next to the cutting blades and you do not have any movement at all, then yess taht will work.

However if there is any gap between the bearing and the cutting blades (which mine had), then you can't do that method.
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Pixelhugger

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Re:Cutting trackball hole in plexiglass (revisited)
« Reply #42 on: November 17, 2004, 01:26:28 pm »
Quote
Still can't find one of these polishing wheels.  What are they made from Pix?  is it a soft material.  I've seen something called a ''flap whee', but this looks to have abrasive 'flaps' protruding from it.

Definitely NOT the abrasive flap wheel. Check here.. this is the type of wheel I used:


http://www.hobbytool.com/index.asp?PageAction=VIEWPROD&ProdID=60

The 3" hole saw will leave a hole a bit larger than the hole in the mounting plate.
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ras2a

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Re:Cutting trackball hole in plexiglass (revisited)
« Reply #43 on: November 17, 2004, 01:38:14 pm »
The way I see it, if the router bit is tight within the router and a steady-hand used, then there can be no movement up and down and therefore no chance for the router bit to 'dig in' and ruin the trackball plate.  Does this approach look ok and is this the method used by some other people?

As long as the bearing on your bit is right next to the cutting blades and you do not have any movement at all, then yess taht will work.

However if there is any gap between the bearing and the cutting blades (which mine had), then you can't do that method.

Yeah, I actually edited my post earlier as I didn't read all of the replies to this thread.  Well I guess I'll have to use another method.  I've just measure the trackball plate hole diameter and it's approx 3" and 2/8" (about 84mm).  I'm gonna have to think of an alternative solution!

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Re:Cutting trackball hole in plexiglass (revisited)
« Reply #44 on: November 17, 2004, 01:45:40 pm »
3 2/8"?? Hmmm. Maybe I used a 4" hole saw. I'll have to check when I get home.
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ras2a

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Re:Cutting trackball hole in plexiglass (revisited)
« Reply #45 on: November 17, 2004, 02:00:47 pm »
3 2/8"?? Hmmm. Maybe I used a 4" hole saw. I'll have to check when I get home.

Im using a Happ High-Ball trackball and high-ball mounting plate.  The 'actual' hole size in the plate itself is about 3 2/8" (it deffo over 3").  So, I assume that the combined size of the trackball and lip (diameter) is again, approx 3 2/8" - Can anyone who is using/used a Happ High-Ball confirm this?

So then my 3" hole-saw is pretty useless.  I really am scratching my head now as to what to use as a solution.  Could/should I get a scrap piece of MDF and fix this to the tracball plate to make a 3 2/8" template and then use this for the bearing to ride against when routing the lexan?  Does that sound feasible?

Have you ever been at that stage were you don't know what to do and you know the answer/solution is staring you in the face?  Just need a fresh pair of eyes/brain - lol  ;D

Thanks for any help in advance guys

Edit: Thanks for the info on the buffing wheel Pix?  I'll see if I can get hold of one this weekend.

Edit 2: Fractal - Yeah my flush trim bit also has a gap between the bearing and blades....shite!
« Last Edit: November 17, 2004, 02:06:53 pm by ras2a »

Zakk

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Re:Cutting trackball hole in plexiglass (revisited)
« Reply #46 on: November 17, 2004, 07:32:13 pm »
Has anyone mentioned the variable size hole saw?  The kind with a blade that slides out to any diameter?  I use that for plexi and depending on which way you turn the blade, you either get a bevel or a smooth cut.  I usually do a practice cut in some plastic until I fit the trackball in perfectly, then cut the real hole.  Let's see if I can find a link to it...
Ahh there it is: http://www.generaltools.com/product.asp?action=prdupc&prid=56&sectionid=2

I picked it up at HD for like $15CAN so it's pretty cheap, and while it says you can use it on metal...I disagree, but on plastic it'sda bomb!  Oh, watch your knuckles tho.  It's a bit hard on them if you get too close!  :o
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ras2a

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Re:Cutting trackball hole in plexiglass (revisited)
« Reply #47 on: November 19, 2004, 11:26:28 am »
WooHoo I've just been to chat to our carpenter in our woodworking section at work and he has the exact tool mentioned by Zakk

(http://www.generaltools.com/product.asp?action=prdupc&prid=56&sectionid=2)

However this one actually has two cutting blades, as opposed to one.  I'll do as you did Zakk, and simply parctise on some scrap pieces to get the EXACT size first and then go ahead on the lexan

Cool, I'm well chuffed now.....ask and it shall be given unto thee :)


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Re:Cutting trackball hole in plexiglass (revisited)
« Reply #48 on: November 19, 2004, 02:49:01 pm »
MAN! I wish we had a woodworking section at work.
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ras2a

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Re:Cutting trackball hole in plexiglass (revisited)
« Reply #49 on: November 19, 2004, 07:19:09 pm »
Yeah it's pretty useful.  Wish I had a workshop of my own though, that way this project would have been done in less than half the time that it's taken.  Just be glad to get it all finished and start enjoying the fruits of my labours.  Just like to thank this board as a whole as you guys are one of the most helpful groups of folk around.  Great community spirit around here.  And special thanks to pix for helping me out in his own spare time - cheers mate :)

ras2a

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Re: Cutting trackball hole in plexiglass (revisited)
« Reply #50 on: November 22, 2004, 11:32:46 am »
Just cut out a hole from MDF (same size as trackball plate hole dia..about 82mm).  I can now use this extra depth for the router bit to ride against when cutting my lexan.  Yipee...just need to drill some holes in this scrap piece so I can sit the piece on the underside of the plate.


coasternuts

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Re: Cutting trackball hole in plexiglass (revisited)
« Reply #51 on: November 22, 2004, 03:51:11 pm »
This is probably a silly question, but does everyone use
a drill press for their holes, or can you free hand it with
a hand held drill?

ras2a

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Re: Cutting trackball hole in plexiglass (revisited)
« Reply #52 on: November 22, 2004, 07:22:34 pm »
This is probably a silly question, but does everyone use
a drill press for their holes, or can you free hand it with
a hand held drill? 

If so, can the variable hole cutter work in a hand held?

I really like those bevel cuts, and that polish looks
freakin sweet!!  Nice job.

-Coasternuts


Hey Coaster, I drilled that hole earlier using a pillar drill.  The reason for this?  Quite simple really, my hand held drill (crappy Black and Decker) had nowhere near enough torque to cut the required hole.  So I put the bit in the drill press and it was a breeze. 

Hehe, I know what ya mean about the bevels and polishing...it looks beautiful doesn't it?

ras2a

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Re: Cutting trackball hole in plexiglass (revisited)
« Reply #53 on: November 29, 2004, 09:36:43 am »
Ok, I finally got around to cutting the trackball hole...here's what I did.  I know, probably could have done it a LOT easier (lol), but it worked fine nonetheless.

- Measured trackball plate hole diameter = 82/83mm (Highball trackball plate)
- Got an adjustable hole saw (The 'T' bar kind with slidable blades, adjusted to suit an 82/3mm hole). Cut the hole out of a scrap piece of MDF (MDP piece needs to stretch the depth of the lexan - front to back..to be clamped later.
- Insert trackball plate in CP and lay lexan on top of CP (precisely) - Clamp everything together (again, precisely)
- Turned everything over so bottom of CP/Trackball plate hole is visible
- Marked (marker pen etc) the trackball plate "hole" around the inside so you now have a circle on the lexan.
- Un-clamp everything and remove the lexan
- Line up the MDF piece with hole in it, EXACTLY around the 'circle' just marked out on the lexan, and clamp making sure to be precisely alligned
- Drill/route a hole through from the top (big enough for flush trim bit to slot through)
- Insert router with flush bit and flush trim the lexan back to 'match' the hole in the MDF piece that is clamped underneath.
- Un-clamp MDF piece and lexan
- Ensure CP has trackball plate inserted and test lay the sheet of lexan over the top - If everything went to plan, the hole in the lexan should now perfectly match your tracball plate hole
- Grab an ale to celebrate this seemingly easy yet somewhat head-scratch inducing conundrum...well for me at least :)

I haven't bullnosed/chamfered my hole (sounds ominous) yet, but do plan to.  I'm still looking for a dremel type polishing wheel to give it a sheen, once done.  Although I came across a great UK site for power-tools etc (www.tooled-up.com)...maybe they will have something similar?

EDIT: the piece I cut in the pic in my above post was scrapped.  My above method used a seperate piece alltogether - Just so folk don't get confused.

Craig


« Last Edit: November 29, 2004, 09:41:39 am by ras2a »

teef two

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Re: Cutting trackball hole in plexiglass (revisited)
« Reply #54 on: November 29, 2004, 11:40:31 am »
For the polishing you could always use a dremel or dremel type tool. The dremel clones they sell at B&Q usually come with polishing bits and are not that expensive.

I used this for cutting out my trackball hole. Just put an arasive bit on there and traced around the outside of the hole. Then trimmed by freehand.

ras2a

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Re: Cutting trackball hole in plexiglass (revisited)
« Reply #55 on: November 29, 2004, 04:11:16 pm »
cheers for that, teef

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Re: Cutting trackball hole in plexiglass (revisited)
« Reply #56 on: August 27, 2006, 01:38:09 am »
[Bump]

Why does it matter how you cut the hole for the trackball?  Isn't the metal trackball mounting plate going to cover the plexiglass?  As lon as the hole is bigger than 3" diameter but less than 6", the mounting plate will provide a perfect opening and the rest of the plexiglass will be hidden.

Or were the people here talking about not using a mounting plate?

Jason

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Re: Cutting trackball hole in plexiglass (revisited)
« Reply #57 on: August 27, 2006, 01:40:43 am »
Right. They were discussing a blind mounting where the mounting plate is hidden beneath the plexi and CP artwork.
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Zakk

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Re: Cutting trackball hole in plexiglass (revisited)
« Reply #58 on: August 27, 2006, 10:48:45 am »
[Bump]

Why does it matter how you cut the hole for the trackball?  Isn't the metal trackball mounting plate going to cover the plexiglass?  As lon as the hole is bigger than 3" diameter but less than 6", the mounting plate will provide a perfect opening and the rest of the plexiglass will be hidden.

Or were the people here talking about not using a mounting plate?

Jason

exposed mounting plate is a serious MAME faux pas.  Don't remember ever seeing a missile command or a marble madness with an exposed mounting plate.    :)
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Re: Cutting trackball hole in plexiglass (revisited)
« Reply #59 on: August 27, 2006, 04:27:54 pm »
exposed mounting plate is a serious MAME faux pas.  Don't remember ever seeing a missile command or a marble madness with an exposed mounting plate.    :)

I'm gonna do an all-mounting plate CP.  Exposed trackball plate, exposed joystick plates, maybe I can even fabricate some button mounting plates to leave exposed.  Put that in your pipe and smoke it, MAMEY-Man!  :P

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Re: Cutting trackball hole in plexiglass (revisited)
« Reply #60 on: August 27, 2006, 09:20:09 pm »
So you're going to make a slikstick?
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