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Tips on drilling and cutting plexiglass for CP
y2k600f4:
hmmmmm....which I read your post Zakk before I cut my CP plexi. I sucessfully drilled out all 19 button holes and 2 joystick holes (still need to do trackball, once I know the dimension of the hole). Cut using the jigsaw method, slow speed, fine blade. Worked good until i got to the end and the blade snagged.....and resulted in about 1" crack in the corner. Guess I will live w/ it for now :'(
Zakk:
If you check out my project pages, you will see that almost ALL of them ended up just like yours. Problem is, when the panel is almost done, there is very little structural integrity left, so it's easy to snap crackle and pop it. The router was the only thing that seems to eliminate the problem.
crsdawg:
zakk is right on...use a flush trim bit for the edges and a panel pilot bit for the holes (the latter has a drill bit built in that will punch through the material, makes doing the button holes a one step process).
the cps come out perfect every time. just make sure to wipe away all the acrylic chips after each hole, otherwise you will most likely scratch the plex (they get sandwiched under the router and can cut through the protective plastic film on the plex/lexan/whatever your using).
cadis12:
--- Quote from: More Cowbell on June 21, 2007, 10:52:02 am ---
--- Quote from: Jouster on June 21, 2007, 08:07:13 am ---One tip though...melting plexi/Lexan isn't as cold as you'd first think...don't wear sandles!
--- End quote ---
Great tip. Also wear goggles. I got nailed in the eyeball with some molten plexi once. When I closed my eye quickly, the plastic hardened and seald my eye shut! It hurt like hell and I thought I was going to have to go to the emergency room but I peeled it off of my eyelids (losing a few eyelashes) and ended up with some minor redness and itching for a few days. Could have been much worse. Debbie Downer signing off.... ;D
--- End quote ---
When I started cutting my control panel for the first time I started with a router and it was going so well that I didn't want to stop. I had goggles in the basement but didn't want to stop to go get them. So I kept going with my eyes squited. Stuff was flying all in my face. Wasn't a big deal. Felt like I had a few particles in my eyes but it was cool at the time. Then later that night I went to bed and when I would shut my eye lids and keep them closed it felt like sandpaper!! I couldn't sleep all night cause I couldn't shut my eyes!! I learned my lesson and I hope others read this thread and take the time to put gear on.
cadis12:
Oh, and the flush trim bit is my new best friend!
:notworthy: