Allright....enough jokes about the size of my control panels. Isn't a king size bed better than a queen?
Let's talk about plexiglass. I was terrified of plexi until I just decided to start cutting. I usually get a piece from Home depot that's 30X40" for $19.99. I can usually get one CP plus the front and back of a 25x7" marquee cut out of one piece. A jigsaw and a router is a must to do quality work.
I'll cut my control panel out of 5/8" MDF. Drill all the button, joystick and trackball holes. Use a small slotted router bit for the t-mold edging.
I cannot stress enough that you need to make a slot around the edge at least 1/8" smaller than the width of your t-mold nipple. You definitely want to have to tap the t-mold into the slot. No glue should have to be used.
Test fit the t-mold on a scrap piece of MDF. The t-mold should end up being flush with the plexi once it's placed on top of the MDF. This is important because once you tap the t-mold into place, it will effectively hold the plexi flush with the top of the control panel.
Once you have the CP cut to size, I lay it on top of the plexi and trace about 1/2" extra around the outside diameter. I bought a jigsaw bit specifically for plastic available at any hardware store. SLOWLY cut the perimeter of the tracing always making sure to keep the plexi flush between two pieces of wood to minimze vibration which will crack the plexi. Then you lay the oversized plexi on top of the control panel and clamp it down so it won't move. Set your router bit to the correct height and cut the top. It's easy if your bit has the bearing guide on the bottom. The plexi should end up being perfectly flush with your CP edge. Use compressed air or a brush to keep any scraps of plastic off your work during this process, Stray scraps can scratch your plexi. You really need to keep the work flush at all times to cut down on vibration.
Here's the scary part. Flip the whole thing over, so that the plexi is sandwiched between a solid piece of wood and your cut out contol panel. Use a sharp 1/2" wood bit and drill a hole in the center of each button, joystick and trackball hole. Wether you drill fast or slow, it still gets a bit hairy and the plexi seems to crack a bit, but never more than the circumference of the actual button hole.
Once you finish the drilling, clean off the panel once again. Flip the panel back over so that the plexi is resting on top of the MDF. Clamp it down in place so that your edges match up again. Start your router and drop it into each drilled hole. Do not start the router while it is touching plexigalass, you will crack the plexi!
We all use a trackball mounting plate. I always counter sink the plate into my panels. Fill in the edges with a little wood filler and sand smooth with the mounting plate. When it comes to routing the hole for the plexi around the trackball, you need to be carefull. At this point it is very easy to set your router at the wrong height and accidentally cut the metal of the mounting plate. It's easier to set your router bit too high and make an adjustment. Once you set it too low, you are in trouble.
If you are feeling adventureous and want to mimic a Golden Tee machine, use a bit with a small chamfer, set your bit high enough so that it's just cutting the plexi and just trace around the inside edge of the trackball hole. You will end up with a 45 degree beveled edge for the trackball. It's a real classy touch. Remember, let the bearing of the bit be your guide. It's almost impossible to mess it up if you rely on the bearing.
From here, I apply my graphics and cut out all the holes and edges with an exacto knife. Clean the plexi front and back and lay it on the CP. Attach the buttons and tap the t-mold into place. At this point you should have a great looking panel which will be held in place by the buttons and T-mold
If anyone can add their ideas to make this process better, I'd be glad to hear it. Let me know if I've explained things poorly!
John