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Installing a 3" USB Happ Trackball: do I *have* to use the special mount plate?
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xmenxmen:
If you have a router, cutting plexi with it is like cutting butter.  No need to do any sandwiching or anything like that as long as you are using the router to do the cutting.  Using drill or something else, that's another story and will need to take some time and effort not to crack it.

I would cut the hole on mdf or wood first, then us it as a template to cut the plexi using your router.
ARTIFACT:
interesting information here thanks guys!
i do have a router and will use it as much as possible...

i have a couple of questions about router usage:

. how do you cut 1 1/8'' button holes with a router?

. also, is there a post explaining the concept and howto for router templates?

thanks
xmenxmen:
Cut the wood 1st with either a 1 1/8 spade or holesaw first.  I found making the hole using that is easier than using the router.  For me, spade bit is a bit faster.

Then add the plexi to it on top (assuming you are using a flush trimmering bit, the one with a wheel at the bottom).  Make sure to clamp it down tightly. 

Now take a straight trimming bit and make a small hole in each hole that you have created thru the plexi.  The small hole need to be bigger than the flush trimming bit.  You might want to do some practice on this before attempt on the control panel, but once you get it, it's quite easy to cut the plexi.  What I do is put it into each hole slowly letting the router bit melt the plexi, then gentally left it with both hand and move to the next one.

Once all the hole has a small hole, switch to the flush trimming bit and round off each hole. 

That's it.
ARTIFACT:
thank you for posting these details

I already have a 1 1/8" hole saw and used it on my 1st prototype CP

Newbie Question: so the flush trimming bit "slides" along the 1 1/8" hole in the wood?

I am new to routers - I used it to cut my speaker grill slots and round some edges, but not to do this template stuff :)
xmenxmen:

--- Quote from: ARTIFACT on August 21, 2007, 12:49:51 am ---thank you for posting these details

I already have a 1 1/8" hole saw and used it on my 1st prototype CP

Newbie Question: so the flush trimming bit "slides" along the 1 1/8" hole in the wood?

I am new to routers - I used it to cut my speaker grill slots and round some edges, but not to do this template stuff :)


--- End quote ---

Yes.  see. picture.  In your case, the top wood is your plexi.

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