My hole is rough as a badgers arse!

[JoyMonkey]

err... yeah.

Here's the problem:
I've got my aluminium control panels cut to suit my layout, but the hole that was cut for the joystick is way too rough around the edges (check out the blurry dusty photo).



How do I cover this up?

Getting plexi or lexan cut to cover the entire panel and leave nice smooth holes from the joystick and buttons would be great, but way too tricky and expensive right now.
Can I get somehthing that will just cover the rim of the hole?
I've run out of ideas again.

JoyM.

[SirPeale]

If you have a rotary tool (and why wouldn't you?  You're a man, right?) use a grinding wheel to smooth the inside down.

Failing that, some sandpaper will do the same, or use a file.

[Amra]

What you might look for is something like a rubber seal, many have a lip, which would cover that area quite nicely...

Problem is, finding one the perfect size

[AlanS17]

I would recommend a cutting tool (Dremel) with a grinding bit. A tool file would probably work as well, but you would be wise to use one with a rounded back. Sand paper won't fix it.

Your best bet is to use a Dremel. Hopefully you have one already because the grinding bits are probably only $2 or $3. A good tool file might run $10.

[bionicbadger]

 

After seeing the title, I thought I had to comment on this thread.
I just don't know what to say...
   

[AlanS17]

He never mentioned anything of a bionic badger, though... I would imagine that would be shiny smooth.

[Spaced Invader]

I'm not exactly a rough hole expert...though I have encountered more than one.  

Hmm...

Maybe you could make a bezel of some sort--mini Cd covered with Vinyl maybe? Just adding my thoughts to the list...I'd try the dremel or rubber seal first...but what do I Know?

And there's always Duct Tape!

[Xiaou2]

 Actually, Dremels Stink.  I hardly ever use mine... as its dangerous... and the tools (cutting/sanding/ect) fade away too fa$t to do any large heavy duty work such as needed here. (also slow to do large work)

 You can pick up some Much heavier duty grinding bit ends for your drill.   Use these to gring the surface flat - then touch up with sandpaper in varying grits till smooth.

 Ive use these drill grinder bits with my drill press for excellent results.






 

[gndprx]

Not normally one to state the obvious here, but a simple file would clean that up in a few passes.

Just a suggestion  

[Lilwolf]

But the question is how accurate is your statement?

I mean... did you have the Badger next to your control panel when compairing?  And was it just a visual compareson or did you make multiple tests?  

Now that you've cut it, there isn't much to do but file.

but for next time.  Start the whole from the side you want to be clean.  Start very very slow.  Make sure you have a sharp drill bit.   Not much you can do about it other then that.