This is fairly simple to do yourself, to start off, you need some Plexi-glass. This can be found at a glass shop, Home Depot, or Lowes. My case was made out of  3/8” Plexi-glass, Ό” can be used but you may need to re-measure. The glass can be cut to size with a regular table saw.  

Also, you will need some acrylic glue and acrylic hardware (latches, hinges , and a door pull). You may be able to find these locally or you can get them from AllAcrylic.com which is where I did. Prices are reasonable and if you spend $30 you get free shipping.

Here is what hardware you need:

1 pair of hinges 1-1/2” x 1-3/4”
1 Acrylic pull (Small)
1 door catch

They also sell the glue and an applicator ( I used a small syringe).

 Next, you need some 80 grit, and 240 grit sandpaper ( or something close)  which can be found at Wal-Mart. The 80 grit is used for the glue joints and the 240 is used for smoothing the edges. 

 1) Cut the Plexi-glass : 2 pcs 21” x 11”    ( Front & Back)

                                      2 pcs 10 Ό” x 3”     ( Sides)

                                      2 pcs   21” x 3”     ( Top & Bottom)

    Note: These dimensions are FINISHED dimensions. I recommend you add Ό” to each measurement so you can dress the edges. 

2) The table saw will leave a very rough edge.  If you have access to a Jointer, you can smooth the edges somewhat with it.

Make sure the depth is set for no more than 1/16” or it will chip the glass. Run all of the edges through once then measure for the final size. If it is still not the right size, continue to run the edges through until it is the right size. 

3) Using the sander with 80 grit paper, sand the edges so they are visibly smooth. 

Using the sander with 240 grit paper, sand the edges that will be seen ( All 4 edges on the front & back, and 1 edge on each of the sides, top & bottom). Sand these as best as you can they will be flame polished to look like finished glass.

 FLAME POLISHING:

Flame polishing is  , economical method of edge polishing that is preferred by some fabricators. Do not use this method on edges that will be glued or crazing will result (The fine cracks to the left)

The flame should be bluish, nearly visible, approx. 4” long, and narrow. Hold the torch so that the tip of the flame touches the edge of the acrylic sheet. Move the torch along the edge at a speed of approx. 3”- 4” per second.

 Overheating and bubbling may occur if the flame is moved too slowly. If the first pass does not produce a completely polished edge, allow the piece to cool; a second pass will often improve the surface finish. 

4) After all the edges are done, wash the glass with soap & water. DO NOT use a cleaner such as Windex   The ammonia in it will cause the glass to turn yellowish over time.  

5)  Dry fit the bottom, sides, top, and bottom. Check to see if the wood display will fit inside still. It should be a tight fit. If it seems to be too tight on the top and bottom, don’t give up just yet. It will fit. 

6) Glue the sides together. Be careful the glue is liquid and a little bit goes a long way. That is why I used a syringe, put a fine bead along one edge and butt together. The glue sets pretty quickly. If you have a frame clamp, you can glue them all together. If not, glue one joint at a time. You can use anything on the inside to square it up. Use masking tape to hold the joint until it is set. 

7) Glue the back on next.

8) If you plan on mounting the case to the wall, drill holes through the back.

9) Lay the lid on top and tape it in place. Place the tape where its not in the way of your hinges and door pull. Glue hinges and door pull ( Allow the hinges to dry COMPLETLEY or they will break ).

12)  The case is complete!! Check for fit. I made mine snug so it wouldn’t come out. What I did was put the wooden case in the freezer for a few hours and I let the case set in the sun. Freezing the wooden case made it shrink, the sun expanded the case. Take the case and mount it, then slide the wooden one in. Once the temp was equal, I had a snug fit.   

Any questions, comments?  Contact me at MarkU88@ntelos.net