cutting lexan for control panel top/trackball mount

[ahofle]

I am to the step in building my cabinet where I am cutting lexan for my control panel top.  I didn't have much luck at all using the lexan cutter tool and then bending and snapping the lexan, and I spent about 15 minutes repeatedly scoring the damn thing with that blade, and it would still not break consistenly along the line.

Anyway, I finally got a decent cutout and I am to the point where I need to cut out a fairly large circular hole for my trackball to be mounted.  Does anyone have any suggestions for going about this?  I pray to god these suggestions do not involve that useless lexan cutting tool, lest I end up using it to slit my wrists.  Will a dremel work?  I assume a jigsaw is much too slow and will crack the plastic.

Also, the metal trackball mount plate sticks up about 1/16" to 1/8" from the surface of the wood.  Will the lexan be ok to cover that or will it look weird being uneven?

Thanks,
Andy

[TheTick]

You can get a hole saw for your drill from Home Depot (not a spade bit). Attach a piece of scrap wood under the plexi. And then drill thru the plexi (actually it will mostly melt thru it).
Worked on my old control panel, I think I used a 2 1/2" for my trackball hack. They sell a variety of sizes, but you'll also need a mandrel to attach it to your drill.

Otherwise use your dremel and a cutoff disc. I would still use some scrap wood underneath. The circle would be as perfect, would need some sanding, and if the dremel skips across the plexi... you're gonna be pissed.

[JesterDEV]

What I did was just drill my whole (as stated above) in the wood, then use the hole as a guide.

[ahofle]

Hmmm, do they make 3inch hole saws?  Hadn't thought of that.

[TheTick]

Hmmm, do they make 3inch hole saws?  Hadn't thought of that.

Yup. You'll probably just better off asking someone local if you can borrow it, you'll probably only use it the one time.
Or you can be an a**, buy it from Home Depot, use it, and get a refund within 60 days.

[u_rebelscum]

Also, the metal trackball mount plate sticks up about 1/16" to 1/8" from the surface of the wood.  Will the lexan be ok to cover that or will it look weird being uneven?

To make it look nice, you should route out the wood 1/16" so the top of the plate is even with the top of the wood.  A router would be the easiest to do this with obviously, but you could chisel it out.  Plywood would be the easiest to chisel.

Here's how I'd do it with a chisel: use the cutout template on the wood and mark: the cutout for the TB case, the four holes in the corners to hold the plate, and the outline of the plate.  Cut the cutout.  Drill the four bolt holes for the plate, slide the plate onto the CP, and check the outline.  Redraw the outline to the actual plate edges if different.  With a chisel, cut straight down along the whole outline (don't worry too much about going too deep, but be sure to go at least 1/16" down).    Chisel from the inside toward the edges, being careful around the edges.  Go slowly, checking the depth by sliding the mounting plate into place.  It doesn't need to be absolutely flat, but closer you can get it to flat, the better.  Chisel or sand as needed.  

After done, screw in the plate, fasten the lexan to the board, put a piece of wood on the other side of the lexan, and use the hole in the mounting plate to guide the hole in the lexan.  (much others suggested cutting the lexan)

[ahofle]

Thanks for the great information.  One question though, does happ usually send templates with their controls?  I've spent a couple hundred dollars on parts from them and I haven't gotten one single template, for joysticks or trackball.  Is there anyplace I can download/print something?  I'm not even sure which screws to use but that's another story.

[TheTick]

They have PDF files of all the templates and mounting views on their website. They are on the same pages that list the part numbers. Just look for buttons that says"Mounting" or "Exploded" views.