Drilling plexi for control panel

kruuth

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I need to make a plexi overlay for a 3-button 2-player panel. I don't have the original. Any advice for making a nice panel? Last time I tried tracing and messed it all up.
 
Measure twice, cut once. If you have access to a step bit for a drill (and even better, a drill press) use that to drill the holes. Otherwise a 30mm bit is what you're after.

If you can use the control panel as a template and have access to a router, even better.
 
Yeah I have the control panel. My problem is that being the undrilled plexi on there.

Should I tape it down and then trace the holes from the back?

Also, the panel has very large joystick holes. I'd like to make them smaller in the plexi.
 
Run the drill in reverse so that it doesnt pull up on the plexy but pushes down against it. This technique prevents nearly all cracking.
 
Yeah I have the control panel. My problem is that being the undrilled plexi on there.

Should I tape it down and then trace the holes from the back?

Also, the panel has very large joystick holes. I'd like to make them smaller in the plexi.

Yes, use the CP as a template, but make sure to clamp down the plexi very well so it doesn't move while you trace.

Interesting technique on drilling in reverse. I've never had to do that with a hole saw (30mm) or step bit running at high speed tho.
 
I clamp mine on to the control panel and use a sharpie to trace the holes, or in some situations spray paint. Next use a T-square and try to mark the center line of the holes in both vert and horiz orientations. This is helpful if your hole saw has a center bit, that way you line up the bit on the X in the center of each hole and the hole is perfectly centered. Put masking tape on the back of the plexi and lay it on a scrap piece of wood for support and to prevent cracking. Don't push too hard, let the drill do the work slowly. I have a fine toothed hole saw just for plexi/lexan. I use a portalign to be sure I am straight and controlled. It's much cheaper than a drill press and is easy to move around and store when not in use.
 
I've not used at square. I take it there's some literature on how to do it online?
 
drill backwards trick above is a great answer.

use a soldering iron to make a starter hole, then drill backwards with a 1-1/8 hole saw. works slick and fast and you won't crack anything.

milwaukee-hole-saws-49-56-9663-64_1000.jpg
 
A T-Square uses the straight edge of something to dictate that your line is perpendicular. You can use lot of different devices to do that, it just helps make sure you have a straight line of buttons.

I use this kind of Milwaukee bit for Plexi:
 

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I can vouch for the backwards trick as well, but nothing beats the finish from using a router with a laminate trim bit, they come pretty small so if you have a template and a basic starter hole it makes short work of it.
 
I highly suggest buying lexan material rather than any other plexi material. It is extremely difficult to ruin lexan while drilling.

You'll also have a more durable end product and won't likely need to replace it due to cracking anytime nearly as soon. Eventual spider cracking around bolt holes should also be diminshed or non-existent.
 
I highly suggest buying lexan material rather than any other plexi material. It is extremely difficult to ruin lexan while drilling.

You'll also have a more durable end product and won't likely need to replace it due to cracking anytime nearly as soon. Eventual spider cracking around bolt holes should also be diminshed or non-existent.

this. Lexan is a better product for this application.
 
there are special drill bits for drilling plastic

they have longer "tips" so they don't crack the plastic. the longer tip removes the plastic out of the way so the bit has a place to go and the plastic does not crack. drilling backwards sounds like a good solution for those with no access to the plastic drill bits

I got mine at a store that sells plastic in sheets but home depot and loew's does not sell these drill bits
the plastic store also sell the special skill saw blade or table saw blade for cutting plastic too
 
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