Not a particularly big deal, but I’ve been planning to do this for three years: a Plexiglas display case for a ship model that my wife’s grandfather built. Three years ago, we moved into this house that her grandparents bought the year she was born, to take care of her mother, who has dementia.
The original case consisted of four loose pieces of glass only held in place by the slots in the wooden base and matching top piece of wood. It was a delicate and precarious assembly. Moving it risked it falling apart and damaging the model. So I took it apart and discarded the glass, planning to rebuild it in Plexiglas.
Fast forward three years, and my brother-in-law is moving his mother out to Kansas this week, where he will take care of her. So I decided a couple of weeks ago that now is the time to finish the case so it can be shipped out to them.
Decades ago I had done some construction in Plexiglas, so I remembered the basics, but back then I had a table saw to cut the material. I don’t now. I reviewed some YouTube videos to learn about the score-and-snap method of cutting, which took some practice, and still often didn’t yield perfect results. Then I realized that I could get much better cuts using my router.
In the end, with mistakes and material used for testing, I had just enough left to cut the four pieces I needed, and I cemented them together without any major flaws.
Here is the case by itself, upside down, resting on the top piece:
Right side up, enclosing grandfather’s model:
(NB: I claim no credit for the beautiful model, built from scratch probably in the 1950s or earlier. All I’ve done is stick four pieces of acrylic together to protect it.)
If you look closely, the case is not perfect. In the first picture, the top edges of the pieces are slightly different heights, by 1/16th inch or so, but this has no practical effect when the case is assembled. Slightly more annoying is the fact that the big front and back pieces are about 1/16th short in width, because when you use the score-and-snap method you lose about that much to the scoring and sanding. I didn’t realize that when I was measuring.
If you look closely, at the bottom right there’s a slight gap where the pieces don’t meet. The 3/32-thick material is flexible enough that I could cement it for most of the vertical join, but not all the way to the top and bottom.
My BIL has assured me that this is good enough for all practical purposes, and I think it will probably hold up just fine for quite some time. But the perfectionist in me is inclined to buy another sheet and, using the router for all the cuts, remake it to a higher degree of perfection before shipping it out west. With the experience I’ve gained making this one, the next will be much quicker and easier. (And the third would be even better!)
Nevertheless, I’m pretty pleased with the results, and glad that, whether I redo it or not, this family heirloom will finally have the protection it deserves.