Creating a Control Panel

thefader

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I have a piece of Lexan, and board im going to drill 1 1/8" holes in. Is the best way to do this drill the board, then clamp the lexan to it, then drill the lexan.

OR

Clamp the lexan to the board and drill through the board into the Lexan at the same time?
 
Clamp the lexan to the board and drill through the board into the Lexan at the same time?

Yikes, no. You'll most likely crack the lexan. You'll find your best results will be with a router and a flush trim bit, using your wood cp as a guide to cut the lexan.

As far as the wood cp, you can use a standard spade bit to cut your 1 1/8 inch holes. Then clamp your lexan to the wood cp. Drill a hole large enough to get the flush trim bit through the lexan (don't push on the drill, let the bit do the work). Then put the flush trim bit through the small hole you just made and the wood cp will be your template for the bit. It'll cut the lexan like butter.
 
Ok thanks, one more quick question, is the joystick hole also 1 1/8"?? Ive heard some people say to use 1 1/2"?


Thank you for your help
 
Yes. Joystick hole is the same size as a regular button hole.

With regards to drilling lexan... it's tricky, but I've done it with a regular spade bit. You have to go very slowly. A hole saw type bit will also work well on Lexan. Again be careful not to crack or melt it.

-Ian
 
clamp the lexan to it, then drill the lexan.

I've drilled Leaxn this way. The board supports the plexi as you drill.

Remember Lexan is pretty unbreakable and has a high melt point. It does scratch easier then normal plexi, but the unbreakable aspect and high melt point, over ruel that for me.
 
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