[sdiy]Re: [sdiy] Cheap method for front panels

[rdrake]

I've done a bunch of modular panels in very similar fashion... except i 

 * print 2 copies to regular paper
 * glue one on with rubber cement, center punch 
   where i'll drill, and then disguard first copy
 * drill, deburr, and clean the drilled panel w/ 
   alcohol & steel wool
 * use industrial spray adhesive to mouth the second 
   copy (w/ overhang)
 * trim the edges, then apply self-adhesive laminating 
   film, wrapping film around the edges & onto back
 * trim the holes w/ an exacto blade 

I like your use of color, but haven't trusted the permanence of colored ink/laser prints, so mine are all boring black&white...

bbob 

>----- ------- Original Message ------- -----
>From: seb at burnit.co.uk
>To: peterc at onwe.co.za
>Sent: Thu, 03 Nov 2005 20:35:50
>
>Peter Cornell wrote:
>
>> Hi Seb
>>
>> using the 'Blue Peter'
>>
>>> method (UK people will know what I mean ;) of a
>computer-printed 
>>> sticker and a layer of sticky-back plastic ..
>>
>>
>> Can you expand on this? Any links?
>>
>I will write it up properly and put it on my
>website soon (I'll mail a 
>link when I do), but to expand on this a bit ...
>
>'Blue Peter' refers to a childrens TV programme in
>UK where they always 
>make things with sticky-back plastic.	It's not a
>well known SDIY method 
>of making panels!
>
>
>I used a sheet of 1mm Zintec for the panel which is
>a kind of steel 
>that's fairly easy to cut and drill and, although
>it feels smooth to 
>touch, it has a very fine rough surface that makes
>it quite good to 
>stick stuff too. (The reason it's made like this is
>so that paint sticks 
>easily to it - this type of metal is very often
>used for equipment cases 
>when it is generally electrostatically powder-paint
>coated, then baked 
>to give a smooth hard finish).  To be honest though
>any type of sheet 
>metal would have done - I just happened to have
>this lying around.
>
>I first cut the panel to size.  Then I printed my
>design on paper, cut 
>it out, and blue-tacked it to the front of the
>panel. I used a 
>(automatic) centre punch to punch through the paper
>where the position 
>marks were printed, marking the drill holes and
>cutouts in the panel.	
>Then I drilled and jigsawed out the holes in the
>panel.  Deburring is 
>important otherwise the sticker won't stick flat.
>
>Next I printed the design onto a normal
>self-adhesive paper label and 
>carefully stuck it onto the panel.  I printed some
>bleed so I just 
>trimmed the edges of the panel with a scalpel to
>get an exact edge.  
>Because the sticker sheet was only A4 size, there
>is actually a join 
>just to the right of the DATA pot area, but you can
>hardly see it ..
>http://burnit.co.uk/sdiy/images/joykontrol/front_pa
>nel_populated.jpg
>
>Then I stuck some sticky-back plastic over the top
>to protect the print 
>and give a smooth glossy finish.  I folded this
>over the edges by about 
>1cm and stuck it round the back to make sure the
>front will never peel off.
>
>Finally I cut through the paper and sticky-back
>plastic with a scalpel 
>around the holes.  This is just a question of
>gliding the blade round 
>the edge.  For the LED display window (the only
>place where the edges of 
>the cutouts will be visible) I cut about 5mm away
>from the edges and 
>folded the flaps around and stuck them to the back
>of the panel.	This 
>gives a really nice edge..
>http://burnit.co.uk/sdiy/images/joykontrol/front_pa
>nel_unpopulated_closeup.jpg
>
>
>Hope this is clear enough .. like I said, I'll
>stick it all on my 
>website soon.
>
>Cheers,
>Seb