Vince Valley - Budget-Friendly Professional Control Panels

A few weeks ago, I started working on wiring for the small layout. I see it as a practice run before working on the more complicated Monk Subdivision. At face value, none of that work is required for the layout. I could have just installed a switch to select between DC power and DCC. But I wanted to try to create zone, control turnouts at distance and install a few fancy LEDs here and there with a neat track diagram.

 

My initial thought was to print a diagram and sandwich it between a 1/8” MDF board and a plexiglass sheet. I design the diagram with Adobe Illustrator using the real metal lever switches dimensions to make sure everything fit the board. Once printed, I built the panel base using a wood frame and a MDF panel. So far, so good. Then, I cut the plexiglass sheet to dimension on the table saw. I wasn’t that happy with the rugged borders, but some careful sanding took care of it.

 

It was just a matter of drilling the holes on the plexi. Something that I would say easy… until after maybe 15 holes, the sheet snapped and was ruined. It wasn’t the first time I experienced this. I was about to cut a new sheet when I checked it the MDF + Plexi assembly was thin enough to accept micro switches and it wasn’t! All that work was for nothing.

 

I explored my options. One was to simply paint or stick the diagram directly on the MDF board and not use plexi. I may use a plastic laminated paper sheet so it would survive abuse. Another idea was to print it on a self-adhesive vinyl sheet. I kind of liked the idea but the cost was starting to be high.

 

Then, I thought about using material such as the ones used by engravers and sign makers. A neat Gravoply diagram with predrilled holes would be perfect. I contacted a local engraver and he had many options ranging from $40 to $120. One made of printed plastic, another with Gravoply and finally, a more professional one make of engraved aluminium. The prices were alright for what I would get, but I discovered Staples was offering sign printing on their online print shop. One material, Dibond, was offered. It’s a sturdy 1/8” plastic core sandwiched between two 0.04” aluminium sheets. Quite sturdy, durable and dimensionally stable. For about $45, I could get two control panels printed on one 12” x 18” sheet. Sure, the diagram would be printed, thus less durable than engraving, but given this is just a test for a small layout, I felt it was alright.

 

Cutting Dibond is similar to styrene

After a few days, I picked up my panels at my local store. I was really impressed by the results. Quite sturdy indeed. Also, it can be cut to size with a cutter. After a few passes through the aluminium sheet and in the plastic core, it’s just a matter of score and snap. The material isn’t brittle, so the cuts are quite clean. You only need to file down the aluminium sheet edges to remove the burrs.

 

You get clean edges using the score and snap method

Drilling is also easy. Just use a slow speed to not melt the material. I had good results with various size of drill bits. Punching a pre-drill hole do help too. The plastic core is relatively “soft” and hold screws very well.

 

Installing the switches was easier than expected. I made sure to not scratch the printed surface with the hex washers. The NCE Power Cab Panel was dropped and screwed in place with small screws I blackened with bluing gun.

 

Half assembled panel with switches and LED holders

Honestly, I really like the professional look and sturdiness of this panel. I have taken care to protect the printed surface when I’m working on it, but it should be alright under normal circumstances. Sure, I wouldn’t recommend printed Dibond for intense use (club layout), but for my need it’s perfect. Keep in mind that at the end of the day, it cost me less than purchasing a sheet of plexiglass at the hardware store and my diagram was professionally printed on it. If you want a DIY budget alternative, I think printed Dibond signs are much better than the traditional approach. Plexi and/or charting tapes are, in many cases, a pure waste of time, money and energy.