How to Make Collectible Cases With Clear Acrylic

Cut the Acrylic Sheet

• 1

  Mark the bottom, top, sides and end of the box pieces on one side of the acrylic. Leave the protective cover on the acrylic until you get ready to glue the pieces together. The widths and lengths of the ends and sides should match the lengths and widths of the top and bottom exactly.

• 2

  Attach the acrylic blade to your table saw. Set the blade at a 45-degree angle exactly. Adjust the blade to extend only 1/8 inch above the acrylic to prevent chipping. Set the guide rails so that the blade cuts through the top of the acrylic sheet exactly along the marked line and slants toward what will be the inside of the box. This will create a 45-degree inward slanted bevel on all four sides of each piece of the box.

• 3

  Test fit the pieces together. Sand the edges smooth, being careful to not round the edges. Another way to smooth the edge is to quickly pass a MAP torch over the edges. Don't use a propane torch.

• 4

  Lay the bottom and sides bevel-sides down. Remove the top protective paper from the pieces and tape the edges of the pieces together.

• 5

  Turn the assembly over so that the V-shaped grooves between the pieces are face up. Pull up the sides to form a box and tape the corners on the outside. The top should set perfectly over the open top. Test fit the lid and then remove it.

Glue the Pieces Together

• 6

  Fill the squeeze applicator with acrylic cement and put the lid on the applicator.

• 7

  Squeeze the applicator to remove the air in the bottle. As you invert the bottle to apply the cement, release the applicator so that the air moving back into the bottle prevents the cement from dripping prematurely.

• 8

  Lay the tip of the applicator along the inside edge of each seam and let the cement flow into the seam. If the edges are smooth and match, the cement will be drawn up inside the seam. When the seam appears clear, the cement has filled the joint fully. Don't overfill the seam. Keep the applicator moving along the seam to the end.

• 9

  Turn the box as you fill each seam so that the seam faces downward to get a gravity assist while applying the cement. The cement sets almost immediately but you need to let it cure for 24 hours before removing the tape on the outer seams.

• 10

  Scrape off any loose bits of acrylic along the edges caused by the cutting process with the back of a hacksaw blade. Draw the edge of the blade along the rough edges to smooth. Use the polisher at high speed (1200 to 4000 rpms.) Rub the polishing head with tallow, then apply the non-silicone polishing compound. Polish only the flat surfaces of the box inside and out, and both sides of the lid. Don't polish the edges. The spinning pad can catch on the sharp edges and fling the box across the room. To use as a display case, flip the box over and use the top as a base. Sit the object you want to display on the base. Then set the box over the object on top of the base to create a clear cover over your collectible.