holes in lexian

[peanut]

after i lay my artwork down, whats the easiest way to tap all my holes in a sheet of lexian? CP is already drilled and mounted on arcade.

[M3talhead]

Line up the lexan over the CP. Use C-Clamps or visegrips and a cloth to hold it in place. Then, if you're going to use carriage bolts to hold everything together, drill those first with a regular bit, or if you have it, score the pilot holes with a Dremel. Then secure the carriage bolts tight and remove the clamps and drill the button holes with the spade bit. Just push down firmly and squarely, and go slow as to not melt or crack the plastic.

Its really not that hard to drill through one sheet. I used a set of Ti bits and a single spade bit.

[Veinman]

I highly recommend a Forstner bit. They cost more than regular hole saws or spade bits, but they do the best job, IMO.

[Knievel]

The best and easiest way is with a router if you have access to one.

Clamp it all together and then plunge through the button/joy locations using the holes in the CP underneath as your guide. You will end up with perfect, burr-free holes everytime. You'll need a bit like this...

http://www.leevalley.com/wood/page.aspx?c=2&p=30184&cat=1,46168,46173&ap=1