Step 3Build the touchsurface frame
The best material I found for the frame is 'Tile Divider', which comes in 6- to 8-foot strips and can be purchased in the molding section of most home repair stores. See the images below for a visual description (rather than try to explain here!).
The frame will fit the Lexan very closely, so you can cut the Tile Divider exactly to size: cut two 8-inch strips, and two 10-inch strips. Once the strips are cut, you should use a T-Square to cut the ends of the short strips to bevel inward at a 45% angle. This will make them fit neatly and snugly as a frame around the Lexan.
You will be mounting the four LED lights on one 8-inch side of the frame. They need to be mounted so they are touching the Lexan through holes in the strip, and spread out evenly along the edge.
It is important to place the holes near the top of the strip, as shown below, so that the light shines into the edge of the Lexan only, and NOT down onto the camera below. Mark the locations of the four holes at about 1-inch, 3-inch, 5-inch and 7-inch along the edge of one 8-inch Tile Divider strip.
Because the Tile Divider is made of soft plastic, you'll need to drill the holes in several incremental sizes to avoid bending or warping the plastic too much. First, drill a small hole (1/16"), then drill one a little larger (9/64"). Finally, drill a 3/16" hole, which is the ideal size for the LEDs to fit through.
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