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Tips on drilling and cutting plexiglass for CP
brock.sampson:
I did mine very similar to Teknique. I used plexi for my cp. I actually had the pleasure of doing my plexi twice. I chewed the plexi and the trackball mounting plate when I was cutting the first one with a laminate cutoff bit. I couldn't set the height correctly for the bearing to hit the mounting plate and the blade to hit the plexi. For round two I got a 3" hole saw and a template bit and cut my trackball hole first. I lined that hole up with the mounting plate on the cp and clamped down the plexi. I used a forstner bit to drill a pilot hole to get the laminate cutoff bit and finish the rest of the button and joystick holes. I got my second piece of plexi big enough so when I was done with the holes I could go all the way around with the laminate bit and get a perfect edge. My advice is take your time when drilling and routing you will save yourself more time in the long run.
More Cowbell:
I have also used the sandwich technique where I put the plexi between two pieces of MDF and cut through all the layers. It keeps the plexi nice and tightly packed so it is less likely to crack. Worked for me.
ahofle:
--- Quote from: unclet on June 20, 2007, 10:22:50 am ---4) Cut/drill slowly so plexiglass melts as it cuts
--- End quote ---
To expand on this, I've found that keeping the drill on the highest speed and using MINIMAL pressure is what prevents the cracking. If you press down really hard (or put the drill on a slow setting) before the plexi starts to melt it will crack. So crank the drill speed and gently put pressure on the piece until you start to see it melt, then use a little more pressure to drill through the plexi.
Jouster:
I started using the cutting tool and a straight edge to break it...but quickly switched to using my router.
One tip though...melting plexi/Lexan isn't as cold as you'd first think...don't wear sandles!
Jouster
y2k600f4:
Thanks for all the tips eveyone ! After work I will be attempting to give it a try !