[sdiy] plexiglass panels for modular?

[Tim Ressel]

All in all, I think aluminum is the better material.
Here are some tips on machining:

1) Layout your holes carefully. Use a dye like Dychem,
or just use a large permanent marker. Cover the area,
then use a sharp object to scribe a line in the dye.

2) Use a center punch to mark the holes. I like the
spring-loaded ones. This gives the drill a place to
start, and prevents walking.

3) Drill a pilot hole. Use a 1/8" drill bit and go
slowly. If it walks, re-center punch and try again.

4) Drill large holes a bit (pun intended) at a time.
If you're making a 3/8" hole, first drill 1/8", then
1/4", then 5/16", then 3/8". Sounds like a lot of
work, but it will produce a better hole.

5) Don't forget to de-burr. Simply use a bigger drill,
and with your hand, spin the drill untill the burrs go
away. Or splurge on a countersink and do it the right
way. On really big holes a round file can be used.

Using these methods I have produced some nice panels,
even with a hand-held drill motor. Of course a drill
press is preferred.

--TR


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