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CUTTING lexan(or plexi) with jigsaw.....
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GamingGreg:
Thanks guys!  :)  Another opinion question.  Would it be best to clamp the plexi onto the wood and then drill the holes in one step. Or would it be best to drill in the wood first, clamp on the plexi on,  flip it over, and then drill through the holes into the plexi? (essentially using the holes as a guide)

Also I take it that joystick holes are 1 1/8", just like the button holes. Is that right?

(SNAAAKE, I don't mean to change topic or hijack this thread, but these questions seem related to the original topic.)
AlanS17:
It's easier (at least for me) to put the holes in the wood first. Plus if the lexan melts with wood shavings on it you wight end up with woody lexan when it melts back together. It's best to keep it clean.

As for the hole size, I use the same for joysticks and buttons. It depends on how close you mount your joysticks to the top. Their throw is slightly less at the base than at the top. So the closer your joystick is to the surface, the smaller the hole has to be. If you're mounting from underneath the wood, you're going to need a very long shaft and probably a larger hole, too. (Oh the inuendos that could be made...)
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