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Step 4Cutting the face plate
You'll need your dremel cutting tool or similar for this.
Measure the area you cut out of the faceplate (not the cutout, but the open space inside your faceplate). You'll need these measurements, but if you cut right they should be the same as your measurements before. You'll notice the scrap you have left from the inside of the faceplate has an angled part to it. So keeping this in mind, take that measurement and line it up on the plexiglass picture frame with one side as the side of the frame and the bottom of the measurement being the bottom of the frame that is right angled. Since you added the thickness of the plexiglass to your measurement before, then added two millimeters, any curvature of the frame will not affect how your card will sit in the wallet. Mark off on that plexiglass picture frame the edges of the measurements, drawing a full line.
For messup purposes add a quarter of an inch (1/4 in) to the two sides that are inside the frame (as opposed to the ones on the edges) and measure a half inch down the angled part and draw a line marking these distances. How exact these three lines are do not matter.
Cut along your outer lines then line this up on top of your plate. If you stick one corner of your angled part of the frame you cut out on to the bottom of the hole you made in the faceplate you'll see that your top measurement hits the top of the hole. This means you did well padawan!
Now use some thick non-clear tape along the insides of your measurement lines. This is to use as a guide for when you're cutting with your dremel. It's easier to see how thick your tape gets as opposed to seeing a line being cut away. After making your tape guides, cut along the very edge of your measurement line without actually cutting the tape.
Do a dry fit to see if your new faceplate center fit into the hole you created. (Your angled section is actually going to rest on the bottom of your faceplate hole, instead of going over it, that's why we made it so long!) Odds are if you did this with the dremel there is going to be some unevenness. Try to spot out these places. You might have to flatten out your plexiglass or your faceplate hole in order to get it to fit. I used a combination attack of my exacto blade and some 320 grit sandpaper.
By now you've noticed how far your plexiglass plate extends into your faceplate by now. Lay your faceplate face down on a table or other flat surface and with your plexiglass plate in place and as flat along the surface as possible. Take a pen and mark a straight line on your plexiglass plate where the the cartridge plastic is slightly raised up. Now take your plexiglass out, tape a straight line all the way across, and cut along the line like before. Now your plexiplate fits perfectly into your faceplate.
Measure the area you cut out of the faceplate (not the cutout, but the open space inside your faceplate). You'll need these measurements, but if you cut right they should be the same as your measurements before. You'll notice the scrap you have left from the inside of the faceplate has an angled part to it. So keeping this in mind, take that measurement and line it up on the plexiglass picture frame with one side as the side of the frame and the bottom of the measurement being the bottom of the frame that is right angled. Since you added the thickness of the plexiglass to your measurement before, then added two millimeters, any curvature of the frame will not affect how your card will sit in the wallet. Mark off on that plexiglass picture frame the edges of the measurements, drawing a full line.
For messup purposes add a quarter of an inch (1/4 in) to the two sides that are inside the frame (as opposed to the ones on the edges) and measure a half inch down the angled part and draw a line marking these distances. How exact these three lines are do not matter.
Cut along your outer lines then line this up on top of your plate. If you stick one corner of your angled part of the frame you cut out on to the bottom of the hole you made in the faceplate you'll see that your top measurement hits the top of the hole. This means you did well padawan!
Now use some thick non-clear tape along the insides of your measurement lines. This is to use as a guide for when you're cutting with your dremel. It's easier to see how thick your tape gets as opposed to seeing a line being cut away. After making your tape guides, cut along the very edge of your measurement line without actually cutting the tape.
Do a dry fit to see if your new faceplate center fit into the hole you created. (Your angled section is actually going to rest on the bottom of your faceplate hole, instead of going over it, that's why we made it so long!) Odds are if you did this with the dremel there is going to be some unevenness. Try to spot out these places. You might have to flatten out your plexiglass or your faceplate hole in order to get it to fit. I used a combination attack of my exacto blade and some 320 grit sandpaper.
By now you've noticed how far your plexiglass plate extends into your faceplate by now. Lay your faceplate face down on a table or other flat surface and with your plexiglass plate in place and as flat along the surface as possible. Take a pen and mark a straight line on your plexiglass plate where the the cartridge plastic is slightly raised up. Now take your plexiglass out, tape a straight line all the way across, and cut along the line like before. Now your plexiplate fits perfectly into your faceplate.
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