Alrighty, first thing's first - the plexi:

That's from Maizey in Pretoria. Those two pieces cost me a meager 18 bucks (ZAR).

Now, Jeff wanted the grille to be dead in the center of a 150x150mm piece of plexi, so i bought plexi at 152x152mm. This is why:

Maizey don't cut the plexi very well, and the plexi usually looks quite bad, with all these jaded edges and what not. So i buy the plexi slightly bigger and sand those edges off.

So i masked it up, getting ready for some sanding:

This is after i had sanded 1mm off each edge:

That was with the 36 grit sandpaper. Once you've done that, you'll need to use finer levels of sandpaper all the way up to 1200. Then, if you want, you can go up to 2000. I'm not going to go into much detail about sanding now though. If you want more details, you can follow my guide on Working With Plexi.

And here it is compared to the useless job that Maizey do:

Now comes the scary part - the holes. These are the holesaws i used:

Those are 28mm and 14mm holesaws. I then drew up the design for the fan grille:

And then drilled tiny 3mm holes first:

I do that so that i can easily guide the bigger drill bits from the holesaws.

All done:

Final Result:

You might have noticed that not ALL of the smaller holes are the same size. This is because a 14mm holesaw is just too big and the holes would be too close to each other. So, to get around that, i did a combination of 14mm holes (the holesaw) and 12mm holes (a drill bit).

I unfortunatley didn't get a chance to polish the edges of this specific grille, but i strongly suggest you read my guide on Working With Plexi and get those edges polished up.

I don't have a photo of this exact grille in action, unfortunately, but i can show you other examples of the same grille i made. Here are three grilles i made for Epiphany, a mod of mine:

Good Luck and Happy Modding!

God Bless

Ettienne