Build Your Own Arcade Controls Forum
Main => Main Forum => Topic started by: Silverwind on March 13, 2003, 12:41:28 pm
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I have some rather sharp corners on the edge of my CP from the lexan...
What is the best method to smooth those corners a little.. does sandpaper work well or should I use something else?
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Here's what I did. Took a LOT of elbow grease, but turned out really nicely.
First, I did it with the plastic protective sheet still attached. Take care if you have already removed it as you may scratch.
First, I used one of those "cheeze grater" style wood planers. NOT the single blade "slicers" rather the rippled, multi-tooth gater ones. Like this one:
http://www.amazon.com/exec/obidos/tg/detail/-/B00002X1ZQ/qid=1047576929/sr=1-1/ref=sr_1_1/102-4630280-4859311?v=glance&s=hi
I basically clamped in the plexiglass in the workbench, then took this planer and went at about a 45 degree angle to the edge, on each edge, on both sides of the edge.
This results in a tiny "bevel" to the edge. If you do a pass at about 30 degrees and another at 60 degrees, or just wiggle it back and forth as you plane, you can create a soft curve to it.
Do not press too hard as you'll gouge and chip the surface, but amazingly this tool worked really well. Note: I was only using "Lucite" not "Lexan" as there are different hardnesses I cannot guarentee this will work on all. Also, you HAVE to do this with at least 1/5th or 1/4 inch thick stuff. Dont use it on thin 1/20th stuff as you'll just break the thing.
Next, I bought some foam sanding blocks, a coarse, medium, fine (and optionally extra fine) grit ones. (Usualy 2 different grits are on a single block, 2 sides with one, 2 with another).
I started with the coarse and worked thru the fine, sanding the curve of the planed edge off. I even did 4 corners (it was an Asteroids cocktail project) and it worked good enough to be covered by the clips.
If you stop at fine, you'll have a slightly frosty edge, a bit more smooth than simply sanded glass, but not clear and as smooth as polished glass edges. Use the extra fine ones to get it clearer/more polished.
This worked for me, and produced a cut-free edge and looks pretty dang nice.
On a 2'x3' piece, all sides sanded, took about 90 minutes to get it "right", minus the corners which were hard.
Good luck!
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(can't try here but...)
How about something hardwarish for the main cuts. Like just a file.
Then, a cloth and toothpaste... I hear it will work great as a polish.
btw, if you are cutting lexan... take the scrap and play with it... Best way (so you don't ruin your new stuff.
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For toothpaste, you need a paste, not a gel. Tartar control pastes work best.
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A dremel with a little sanding drum works. Then just buff it to finish.
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Flame polish the edges with a propane torch. You should experiment on scrap to get the right technique.