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Easiest way to cut all holes in Plexiglass for CP?

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bungy:
+1 for the fostner bit, but I used a 1-1/8" and finished in one shot.  I started drilling from the bottom with the plexi clamped to the top and drilled 1 hole on each (lateral) side of CP.  Then I attached a pushbutton in each hole and removed the clamps, it was easier to move it around that way and there was no way the plexi would shift.  I also used a piece of scrap under the plexi as I drilled.

numbnutz48:
Thanks for the ideas! Now, once the holes are all drilled ant the "LEXAN" is trimmed to fit, What is the best way to secure it to the CP

Beretta:
well the buttons will hold it in place pretty well..

for the outer edges however you'll wanna use carriage bolts.

Franco B:
I find the best way to cut the holes is to use double sided tape to stick the plastic (with the film on) to the CP. I then drill 8mm holes though the button etc holes and then use a 1/4" flush trim bit on a router table to cut the excess. You can also cut the plastic over size and use this method to trim the profile of the CP.

Drilling smaller holes will make the plastic less likely to crack. You should have got acrylic (Plexi) rather than polycarbonate (Lexan) as polycarb will scratch easier than acrylic but it will machine just as easily in that thickness.

In regards to securing the plastic to the CP, your buttons/nuts should be enough clamp the two together.

I wouldn't use carriage bolts personally as I think they look fugly but its down to you. Your plastic should lay nice and flat.

severdhed:
i've never used any bolts in my plexi, the buttons are more than enough to hold it in place.  i guess if the plexi sits above the t-molding, then you may want to bolt it, but i installed it so the top edge of the tmolding sits flush with the top edge of the plexi, so it is quite secure

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