Lexan on 3/4" Control Panel - Getting T-Molding Flush with Lexan

[RoninEditor]

Basically, I'm wondering what you guys do for your control panel tops.  I'm going 3/4 on everything else, then 3/4 t-molding on the regular cabinet edges.  However, I'm going to put Lexan on my 3/4 wood (when I get it) which would make it thicker than 3/4 obviously.  I'm thinking to put the t-molding slot from based on the Lexan (to cap the Lexan at the edge), then put the slot down from there, but that's obviously going to leave a little extra wood uncovered by the t-molding at the bott, then maybe routing an edge to make it flush...?  Is this the 'easiest' way to cap the edge of the control panel?  Or should I just buy a thinner "top" to my control panel, to make the 3/4 t-molding flush on the top and bottom.

Am I overthinking this?

[Neverending Project]

It has been suggested elsewhere on this site that you could chamfer the bottom where the t-molding does not cover. (I only say that it is suggested elsewhere because I don't want to take credit for someone else's idea) I think a chamfer would look better than a round-over, since you won't see the chamfer when standing and looking down at the CP. You still may see the wood if it is a round-over.

[RoninEditor]

Ah!  Great, yeah, I like that!  Thanks for the idea! 

(At first I was like, what's chamfer? haha... Wikipedia's our friend:  http://en.wikipedia.org/wiki/Chamfer )

[sstorkel]

Why not buy T-molding that fits? You can get 13/16" T-molding in a number of colors and 1" in black or white...

[javeryh]

Why not buy T-molding that fits? You can get 13/16" T-molding in a number of colors and 1" in black or white...

It might throw off the overall look of the cabinet since all other t-molding is presumably 3/4"...

[massive88]

Could use a thinner wood for the CP top as well, to make the overall thickness 3/4"

I dont know what you are using, but im pretty sure there is both 5/8" and 1/2" MDF available based on your Lexan thickness.

If you are stuck with the 3/4", I would second the chamfer idea.

[RoninEditor]

Yup, I'm going to be using 3/4" fiberboard and t-molding.  I'm heavily considering using a thinner piece of wood for the top, like 5/8" then using 1/8" Lexan, it might cost more though, vs. using the extra wood from the cabinet sides for the control panel top... but I think it might be worth it to just cough up the extra cash.  There was also a mention of angled cut along the bottom, to make up for the slack, which is also a good solution... but I'm definitely leaning toward the 5/8" topsheet.

ps, if you guys want some free comedy, go to Home Depot or Lowe's and asked where their 1/16" slot cutters or 1 1/8" Forstner bits are... the blank looks are priceless, literally today, "I ain't never heard of that."  LOL  I found my at the local OSH, but I'm assuming ACE would have them too.

[massive88]

I bought my slot cutter at Lowes, after finding that they carried them online and Home Depot does not.

A week later I went and looked again, the slot cutters were marked down from $25 to $5   

Its possible they were phasing them out of inventory with that kind of reduction.

[krisbee]

Yup, I agree with this... Lowes had my slot cutter on sale for $5. 

[RoninEditor]

I also saw them online before cut can't seem to find them, which is why I originally went to Lowe's - hoping to find one.  Hmm.