Hi
Well I have the first one made. I was not trying to make this perfect but just wanted to see how the jig saw would cut and to learn how to drill the holes without melting the Lexan.
The saw blades and drill bits I bought for the Lexan worked perfect. I decided to cut it real fast like I would metal and it cut like butter.
I did the same with the drill bit to see if it would crack or melt and no problems.
It took me about 30 minutes to saw it out and drill the holes.
Now for the fun-getting the paper off.
This was a real learning experience for me. The first side came off glue and paper after soaking it with dish soap and warm water for about 15 minutes.
The second side was the side from hell. It took me 2 hours to get the stuff off. I followed the directions and soaked it no luck.
The directions said to use goo gone and it would take off the glue.
After letting it soak for about 1 1/2 hour and using a thin plastic card to scrape it off it looked like I hadn't done anything.
I remembered I had a steam cleaner to clean my vinyl records. I was getting it ready and dried the plate off real good getting ready to steam it. When cleaning it I used my fingernail to get a big piece of glue off and the whole thing pealed off.
I guess the secret to use goo gone is to let it soak in, dry it good, and peel.
I also just marked the wholes with a pencil so they are a hair off. On my next try I will get some soft clamps and clamp jayb's adapter cover to it and use that as a guide so my holes will line up.
I think anybody can do this and if you buy the bits and blade's made for Lexan it is easy.
I also rounded the corners with my belt sander as the jig saw didn't want to follow the tight curves very good.
Here are some pictures.
Greg
