T-molding, Lexan/Plexi, and a Router

[GAtekwriter]

If I'm using 3/4" plywood for the Control Panel and wish to add a Lexan/Plexi overlay and use t-molding on the CP, are there any roadbumps I should be aware of?  I'm mainly concerned with using a router to cut the groove for the t-molding - with the added thickness of the Plexi, there should be a shift in where the groove is actually cut, but I'm concerned that shifting the groove-cut too far up will weaken the upper portion of the plywood or cause it the edge of the plywood to soften and press down.

I guess the next question is:  should I use a less-thick piece of plywood for the CP to make up for the added thickness of the Plexi so the two together add up to 3/4"?  I see that most of the good colors for t-molding are in 3/4" size, so unless I want the Plexi to be above the t-molding, I need to find a way to make the total thickness of plywood/Plexi equal to 3/4"?

Or am I just over complicating this thing? 

Thanks, all.

Jim

[leapinlew]

Theres a few ways to handle this:

Method 1:
If using a 3/4" CP - purchase a larger piece of t-molding to account for the added thickness of the plexi

Method 2:
Use smaller wood for the CP where the thickness of the wood and the added thickness of the plexi = the size of your t-mold

Method 3:
Cut the groove in the middle of the CP and apply the plexi directly to the top of the CP. Many people do this and have no issues. The clean look of the plexi sitting inside the t-molding is attractive. What some people have done is chamfered the plexi at a 45 degree angle to make it more asthetically pleasing and it can prevent snags. People also chamfer around the trackball for the same reasons.

Method 4
Cut the groove higher in the CP to allow the T-mold to cover the plexi and chamfer the bottom portion of the CP and paint it black. I've never done this, but apparently it works well.

Method 5
Purchase a polycarbonite CP and skip plexi all together.

Hope this helps.

[somunny]

I went with method 4, although instead of chamfering the edge of the plexi, I applied heat from a propane torch to smooth the edge.  It takes some practice but the end result is very nice.

[mountain]

I used method 4 too. Once the T-molding is installed it will strengthen any weeknees from slotting off center. Below is a profile shot of my CP after all of the cuts to give you an idea.

[GAtekwriter]

These are all great methods - I'm sure I'll be able to find the right one.  Thanks, Leapinlew.

Mountain - thanks for including the picture - it does look nice and I appreciate you adding the comment about the potential weakness of the off center cut.  Have you already applied your t-molding?  If so (or when you do), please post a follow-up picture if you can. 

One final question - what tool(s) have been used by members to do the chamfer effect?

Thanks again, everyone.

Jim

[leapinlew]

A chamfer bit -

http://www.mlcswoodworking.com/shopsite_sc/store/html/smarthtml/pages/bt_chamf.html

[mountain]

Mountain - thanks for including the picture - it does look nice and I appreciate you adding the comment about the potential weakness of the off center cut.  Have you already applied your t-molding?  If so (or when you do), please post a follow-up picture if you can. 

I am still working on my cabinet. I will soon be posting some pictures of my CP. I hope to spend time on it tomorrow. You can view my build thread in the Project Announcements section.