My grandson asked for a showcase to display a Lego 3D puzzle he painstakingly assembled.  Started it before Christmas and finally got it done.  Here is the assembled puzzle.

 

 

Here is the assembled case.

 

 

 

I fretted over how to cut the acrylic and found a negative rake saw blade was best to for sawing it.  I had bought a negative rake tooth saw blade for my radial arm saw and kept it when I got rid of it.  Put the blade on the table saw and it worked swimmingly.  Cut like butter and no chips or breaks even when trimming just a sliver off.  The top is removable as is the plastic sheet to aid in the placement of the puzzle.

 

 

We'll peel the protective film off the acrylic when the puzzle is placed inside.  for reference it's 20"LX13"DX15"H.

 

 

 

 

 

You both did a nice job!

Nice! That should keep it pristine for many years!

 Wish I had made one of these for my model ships 

Nicely done Dan. Excellent detail with the brass pulls. It will serve the purpose perfectly. Kudos to your grandson. Excellent patience on his part too.

Also thanks for the tip on cutting the acrylic. Do you recall the blade details, e.g. manufacturer, model #?

US Plastics is nearby, and they cur a lot of sheet plastics to size including the thicker, more expensive stuff like UHMW. They told me they always use a negative hook blade on their table saw. We i had my day job the plant bought a huge amount of UHMW from them for our machines.

Pretty cool Dan.  How old is the grandson?  This should bring a huge smile when he see it!

Perfect Dan! My grandson, turns 8 Monday, is already a master Lego builder. This gives me some ideas when the time comes.   

1 hour ago, Cal said:

Pretty cool Dan.  How old is the grandson?  This should bring a huge smile when he see it!

 

My grandson is 18 and just graduated high school and started college last year. Typical for his age he is into video games big time. I was surprised he took to this puzzle. His dad is into jigsaw puzzles. His great grandmother got him into that.

22 hours ago, HandyDan said:

My grandson is 18 and just graduated high school and started college last year

 

I expect the puzzle and display case will be a big hit in the dorm!  What college, and what is he majoring it... not that that isn't subject to change...

1 hour ago, Cal said:

What college, and what is he majoring it... not that that isn't subject to change...

 

He's at The University of Akron.  Computer programming is his intention.  Seems computer gaming is somehow a sport now and he earned a spot on the team.

On 1/13/2024 at 6:01 AM, Fred W. Hargis Jr said:

US Plastics is nearby, and they cur a lot of sheet plastics to size including the thicker, more expensive stuff like UHMW. They told me they always use a negative hook blade on their table saw. We i had my day job the plant bought a huge amount of UHMW from them for our machines.

I buy stuff from there regularly, too.

 

43 minutes ago, HandyDan said:

 

He's at The University of Akron.  Computer programming is his intention.  Seems computer gaming is somehow a sport now and he earned a spot on the team.

I took  one of my daughters there for a campus visit.  He comment was something like, "Keep driving."  She ended up at Kent State.   But her husband went there before going to NEUCOM, now NeoMed.

Cool case and great use of door knobs. My youngest was into Legos and still has them in storage. Wish I had thought to make a case.

On 1/12/2024 at 11:02 PM, Grandpadave52 said:

Do you recall the blade details, e.g. manufacturer, model #?

 

Sorry it took me so long. 

When I bought this blade I wasn't looking for a fine finish blade.  I just wanted to get something for the radial arm saw to break down rough lumber.  The blade I bought was inexpensive but was new never used when I cut the plastic.  It is a

 

Hitachi 10" 60 teeth

Miter saw blade

Part #115435

Thin kerf

  Nice work Dan.