Take the rubber lining and insert the window edges into the grooves. Work your way around the edges until you have covered every inch of the window with the rubber linings. Then cut the excess off. Below is how it looks like once it's done. Not bad eh??

This things are a pain in the ass!!! Click to enlarge

Finally!!! Click to enlarge

Of course, there is one minor glitch! The linings refused to conform to one of the round edges on the window due to the curve. Need to cut a portion of that groove to make it fit. As for the rest of the edges, it was no problem!! Now it's time to cut the plexi.

Minor problem!! :O(
Click to enlarge

The best way to measure up the plexi is to put it against the window and trace the window shape onto the plexi. The plexi comes with a protective adhesive, that also acts as a marking layer. Do not remove this layer until you are absolutely satisfied with the cut you made to the plexi and after you have drilled all the holes for securing it to the case. You should make the plexi larger, about 3/4" on all sides for mounting purposes. If you accidentally cut it to the exact size of the window, all I can say is get yourself a new sheet of plexi!!!

Change to the normal cut-off wheels, since the plexi is very soft and easy to work with. But be careful so as not to exert to much force or you'll end up breaking the plexi. It shouldn't take you long to cut the plexi.

Plexi ready for the Dremel. Click to enlarge

Normal cut-off wheels Click to enlarge

Like hot knife through butter!!! Click to enlarge

Done!! Well...almost! Click to enlarge

Mark out the mounting holes on the case. I will be using some bolts and nuts for securing the plexi to the window. Others would prefer a more permanent method, like rivets. They are a bit long, but that's nothing a Dremel can't handle!!! For the outer side of the window, do not drill through the rubber lining. Use them to hide the bolt heads.

Used for securing the window Click to enlarge

Tada!!! Nice, ain't it? Click to enlarge

See? I told you a Dremel could handle it!!
Click to enlarge

The window is now done!!!! Next up, the neon lights!!!

<< Page 1 | Page 3 >>

 

Got News? Send 'em in!