In 2017 I’m finally going to build a proper control panel for the ICRR. After a lot of thought, given that we have a basement floor layout that changes frequently, I don’t want to do a traditional “track diagram layout” sort of design. Rather, I’m going to use a modular approach – where I’ll create several small panels (maybe a foot square) that then attach them to a lattice framework to build the complete design. Each panel will have different purposes: one for breakers, another for switch controls, a third for accessory switches, etc. This will have the side benefit of breaking the overall work into smaller pieces and limit the frustration should one panel “go awry” in some way.
So, the question now is what to build the panels out of. My design goals are:
- Relatively thin (so that push switches and the like without a lot of “depth” can be easily secured to them) - no more than 1/4" in thickness.
- Strong enough not to flex too much when the controls mounted on them are pushed/used
- Easily drilled and cut without cracking or deforming.
As a starting point I bought some Plastruct .06” styrene sheets – but that isn’t nearly strong enough, even when two or three sheets are sandwiched together. I then searched the forum and found that Plexiglass / acrylic might best be avoided due to its tendency to crack. Several people mentioned using Lexan / polycarbonate with good results. If so, what thickness did you use? Since I don’t want to see through it, I would need to paint the back first (as I haven’t found any opaque /colored Lexan). Are there other sheet plastics that have been used to good effect?
Alternatively, has anyone used sheet metal to make their panels?
