Plexiglass Display Box

What better way to commemorate a great gift, or project, than by showing it off?

After spring cleaning, I found a little robot that my dad had welded for me nine years ago. I wanted to put it up in my workshop, but the amount of dust created would quickly ruin it.

Using a piece of plexiglass and scrap wood, this project is pretty simple, but can quickly become complicated if you don't measure twice and cut once!

Step 1: Tools

Materials

Plexiglass (size based on dimensions of the box needed)

Wood (Size based on dimensions of the base of the box)

Epoxy or other adhesive (preferably the type that slightly dissolves plexiglass)

Tools

Table Saw

Router

Hand router or rotary tool with router attachment

Process

I wanted to have about an inch of spacing on each side of the item, so these dimensions account for it:

Plexiglass:

4.5"X8" x2 Front and back panels

3"X8" x2 Side Panels

4.5"X3" x1 Top panel

Wood:

5"X3.5" x1 Base plate

Table Saw:

Set the bevel angle at 45° and move the rip fence so the blade is pointed towards it.

When cutting plexiglass, feed it very slowly through. I'm talking 1/4th an inch a second. You may need to be even slower, depending if it cuts smoothly or chips roughly. When one side is done, rotate the panel 180° and feed it through again.

When all four sides are done, feed the top panel so it has bevels on all four sides. This will be the topper.

Router:

To add a professional touch, I rounded the wood base with a table router. I went simple, but don't be afraid to add a little flair, more so than a rounded base.

Step 2: Align and Glue

After all panels are beveled, align them up on a miter saw and slowly cut through them. Rotate the plexiglass and cut again, doing so very slowly.

Use bricks, or something square, to align all the pieces, then mix 5 min epoxy (or other adhesive) and carefully applied it to the bevels. Be sure not to overload it and cause it to squeeze out the edges.

Let it dry and set for at least 2 hours (it may be 5min epoxy, but better safe than

After the glue is set, take it to the miter saw and slowly chop both sides so it's nice and level.

Step 3: Top It Off

The final plexiglass piece with all four sides beveled is the top. Glue it with the bevels facing up, and place weights on it. Let set for at least an hour, depending on the glue type.

Another way this could have been done is if three sides are beveled on the side and front/back panels, so the beveling on the top piece could face down.

This will make it look more square, which may be what you're looking for, it just takes more time and doesn't add a whole lot to the finished project

Step 4: Trace and Route

When the clear display box is done, center it on the wooden base and trace the outline.

Use a router or something similar to cut-out an even depth for the display box to fit in. The bit I used was the same size as the plexiglass (1/8th")

Chisel the edges to get them sharp, then sand out any splinters or excess material

Burn:

Instead of staining, I burned the wood with a torch, then rubbed away the soot with beeswax and old rags

Step 5: Insert That Display

There are many ways to secure whatever object you want to display, but I chose a simple method.

Burn off the paper from two bread ties and drill/nail two holes through the base

Cut out a small sliver of wood to create space for the wires

Wire the object through the holes and twist it tight, so there is no wiggle room

Place the box over the base and set it on a shelf. You're done!

Sit back and bask in the glory of your display! Let me know what you think and VOTE!