How to drill Lexan?

[Wolfwood]

Hey Everyone!

After realizing I cannot have my own cabinet, I want to make a stand alone controller, just because I am getting raped at every arcade game without one.

It will be about 11X8 and have a lexan exterior, with wooden supports ( a small box) and I just want to know how I am supposed to drill the holes for my Happs Competition buttons and my Ultra Stick 360? will I need special tools? I already have the pieces cut to my specifications, I just want to know If I will need special tools, or will this box be big enough?

Also, how do I get that nice slick feeling with paint? Like on some commercial plastic controllers?

Thanks A lot! Pictures of the Finished build coming soon!

[severdhed]

i have not worked with lexan, but it should be similar to plexiglass.  here is a thread i started about drilling holes in plexiglass.

basically, i drilled my holes in a piece of MDF, then clamped the plexiglass to the mdf.  then i used a pointed router bit in the center of each  hole to create a hole big enough for a flush trim router bit to fit through, then cut out all the holes using the flush trim bit, using the MDF as a guide.

here is the thread...

http://forum.arcadecontrols.com/index.php?;topic=89334.0

here is the pointed bit i used to make the pilot hole for the flush trim bit...



as for a nice finish..i have found that painted the back side of the plexi with flat black spray paint makes it look really nice from the front.

[MK3FAN]

This is how I drilled my Lexan...

[youtube]http://www.youtube.com/watch?v=5On_kQZZVXc[/youtube]

[1UP]

You can just use a hand drill for lexan though it can take a while.  When I drilled my lexan, my panels were already mounted, so I couldn't use a drill press.  I used a forstner bit for my button holes, which was SLOOOW.  Spade bits would probably work better, just be careful not to push too hard or you'll break through at the end rather than letting the drill do the cutting.

When you have your lexan cut to size, just line it up with your panel, clamp it, and line up the bit carefully centered over the holes in your wood, and drill.

Ideal situation would be to drill the lexan on a drill press.

[FrizzleFried]

Lexan is very easy to drill/cut compared to plexiglass.  I've used a regular bit,  a boring bit,  and even a hole saw with Lexan.  Just take your time and don't press too hard.

[jasonbar]

+1 for using normal tools to machine Lexan.  I've machined a bunch of over the years for my BattleBots.  Just use a normal twist drill, or an end mill, or a band saw, or whatever...it's not prone to cracking or very fragile or anything.

-Jason

[Encryptor]

I used a good sharp hole saw and had no problems when I did my first CP.


Encryptor