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 I'm a lazy SOB, and I seem to have misplaced my ruler, and through my lifetime of lazy projects, I've gotten quite good at eyeballing, so that's how I'm doing this project from start to finish.

First, I traced the outline of the 4" pipe on the lexan, remember I need 2 of these.




I then used the plexi knife to carfully score out my markings, after several passes with the knife, it was evident to me that this was taking too long and was hurting my fingers.

So I went in the other room and cut it away on the outside edges with my dremel (diamond wheel).

I went back to the master piece and scored out the other piece with the knife and finished it off with the dremel. Keep in mind that I'm doing this all with the protective sticker still on the plexi, I wouldn't want to ruin the surface of it.


I then sanded the edges smooth with the 100 grit, then the 400, then the 2000 which almost polished the edge of the plexi enough that it doesn't look frosted anymore.

Then I cleaned up the pipe. I took a sharp knife and carved out the lettering on the edge of one side and flattened it up with the 100 and 400 grit.

Then I placed the plexi on top of the pipe and drilled in lead holes with a thin drill bit (eyeballed of course). Then I used the tap bit and slowly (by hand) screwed the tap down into the new holes.




I cleaned up all my parts and went for the test fit and srewed in some case screws. Nice and tight.

Then I went back and drilled bigger holes for the hose barbs, and tapped them too with a bigger bit.





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