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Cutting trackball hole in plexiglass (revisited)

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ras2a:

--- Quote from: Pixelhugger on November 17, 2004, 01:45:40 pm ---3 2/8"?? Hmmm. Maybe I used a 4" hole saw. I'll have to check when I get home.

--- End quote ---

Im using a Happ High-Ball trackball and high-ball mounting plate.  The 'actual' hole size in the plate itself is about 3 2/8" (it deffo over 3").  So, I assume that the combined size of the trackball and lip (diameter) is again, approx 3 2/8" - Can anyone who is using/used a Happ High-Ball confirm this?

So then my 3" hole-saw is pretty useless.  I really am scratching my head now as to what to use as a solution.  Could/should I get a scrap piece of MDF and fix this to the tracball plate to make a 3 2/8" template and then use this for the bearing to ride against when routing the lexan?  Does that sound feasible?

Have you ever been at that stage were you don't know what to do and you know the answer/solution is staring you in the face?  Just need a fresh pair of eyes/brain - lol  ;D

Thanks for any help in advance guys

Edit: Thanks for the info on the buffing wheel Pix?  I'll see if I can get hold of one this weekend.

Edit 2: Fractal - Yeah my flush trim bit also has a gap between the bearing and blades....shite!

Zakk:
Has anyone mentioned the variable size hole saw?  The kind with a blade that slides out to any diameter?  I use that for plexi and depending on which way you turn the blade, you either get a bevel or a smooth cut.  I usually do a practice cut in some plastic until I fit the trackball in perfectly, then cut the real hole.  Let's see if I can find a link to it...
Ahh there it is: http://www.generaltools.com/product.asp?action=prdupc&prid=56&sectionid=2

I picked it up at HD for like $15CAN so it's pretty cheap, and while it says you can use it on metal...I disagree, but on plastic it'sda bomb!  Oh, watch your knuckles tho.  It's a bit hard on them if you get too close!  :o

ras2a:
WooHoo I've just been to chat to our carpenter in our woodworking section at work and he has the exact tool mentioned by Zakk

(http://www.generaltools.com/product.asp?action=prdupc&prid=56&sectionid=2)

However this one actually has two cutting blades, as opposed to one.  I'll do as you did Zakk, and simply parctise on some scrap pieces to get the EXACT size first and then go ahead on the lexan

Cool, I'm well chuffed now.....ask and it shall be given unto thee :)

Pixelhugger:
MAN! I wish we had a woodworking section at work.

ras2a:
Yeah it's pretty useful.  Wish I had a workshop of my own though, that way this project would have been done in less than half the time that it's taken.  Just be glad to get it all finished and start enjoying the fruits of my labours.  Just like to thank this board as a whole as you guys are one of the most helpful groups of folk around.  Great community spirit around here.  And special thanks to pix for helping me out in his own spare time - cheers mate :)

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