900 D Plexi door 6mm

My friend asked me to replace his broken 900D plexi sidewindow,but from thick plexi (6mm).

I had a 900D sidewindow on my worktable .I studied ,and took measures of the plexi.

Metal door has recess to fit into the slots of plexi.

http://imagizer.imageshack.us/v2/1280x1024q90/911/liVWay.jpg

And There are also ledges at the opposite side of plexi.

http://imagizer.imageshack.us/v2/1280x1024q90/633/dLyu3D.jpg

it is not possible to make these projections , I found another solution.

http://imagizer.imageshack.us/v2/1280x1024q90/907/kfyu0D.jpg

I made holes in diameters of screws at laser.and Then I enlarged them with dremel to 3mm depth of 6mm plexi .

http://imagizer.imageshack.us/v2/800x600q90/903/7O1QQ4.jpg

http://imagizer.imageshack.us/v2/1280x1024q90/910/LNT1rw.jpg

corners were cut of with the same diameter at laser.

Bolts were selected a bit longer because of 6mm plexi. And they are mounted to original places.

http://imagizer.imageshack.us/v2/1280x1024q90/908/YGPtSu.jpg

Plexi mounted , from inside..

http://imagizer.imageshack.us/v2/1280x1024q90/907/ZJvoFB.jpg

and from outside..

http://imagizer.imageshack.us/v2/1280x1024q90/910/iZYzWk.jpg

packeged and shipped to my frend.

http://imagizer.imageshack.us/v2/1280x1024q90/905/oq1yzr.jpg

Another plexi door for Corsair 900D for m y friend vdtkc .But this time slightly different.

http://imagizer.imageshack.us/v2/1280x1024q90/923/nmBWbn.jpg

http://imagizer.imageshack.us/v2/1280x1024q90/923/ZDSmR4.jpg

we want a light strip around the plexi.

this plexi window made from 6mm plexiglas too.

original cover had 1.5 mm protrusion.

for this reason it has no protrude from the metal door

http://imagizer.imageshack.us/v2/1280x1024q90/922/CD0W4K.jpg

but this plexi has 3 mm protruding from the lid.

Processed with cnc router.

http://imagizer.imageshack.us/v2/1280x1024q90/923/uUT6VH.jpg

http://imagizer.imageshack.us/v2/1280x1024q90/924/XjrsAq.jpg

And a light strip was formed all around the plexi with this protrusion

http://imagizer.imageshack.us/v2/1280x1024q90/923/geF2dS.jpg