I use Plexiglas (remaining from a former project). You could use real glass too, but it would require more skills and tools. Plexiglas is very easy to cut, but will get scratches, eventually.
Step 1: Needed Stuff
- 2 mm thick Plexiglas (acrylic glass)
- Hard wood strips (I used beech) of rectangular profiles
- Hard wood strip of round profile
- Cutting mat, metal ruler, cutter
- Wood, paper, and epoxy glues
- Wood primer
- Masking tape
- Clamps (optional)
- Sanding machine (or just sand paper)
- Drill (at best: drill press)
Step 3: Make the Long Sides
- Cut the paper sides,
- glue them on the wood,
- saw them carefully,
- drill (beware: not through) [*]
- with a short piece of rounded profile, put the sides together (without gluing them),
- sand them for perfect alignment,
- soak them very shortly in water, to remove the paper.
Step 4: Make the Board
Hold the Plexiglas between two boards (or in a large vise) and snap it firmly, to break it along the mark.
Repeat to obtain desired size.
Sand the edges. Check that long edges are very parallel.
Check size against wooden sides.
Step 5: Assemble
Glue them to the sides (dip the ends into some wood glue).
Let the glue dry.
Step 6: Make the Short Sides
Glue them with epoxy, use masking tape to keep the right position.
Let the epoxy cure.
Advice: from now on, always remember which Plexiglas board belongs to which frame.
Step 9: Clean and Place the Board
Clean the Plexiglas with water.
Place each Plexiglas into the frame it belongs to.