[sdiy] Plexiglass Panels

[James R. Coplin]

both polycarb and acrylic have enough flex to be annoying and not 
suitable for panels in my opinion.  to make it thick enough to avoid 
flexing, mounting hardware would be difficult. stress around the pots 
and jacks would probably create stress cracks or frosting over time. 
Also, working with either isn't exactly "simple" either.  drilling, 
cutting, and edging can all be touchy unless you have the right tools or 
are willing to have a few rejects in the process.  I find that a router 
works best for shaping it but i recommend special bits for drilling.  a 
standard drillbit is designed to pull itself through the material.  this 
is fine for most materials but tends to break plastics or melt a rough 
hole as it goes through.  you need bits with a 90 degree point and a 
zero degree rake.

James R. Coplin