I think the pictures arent showing up as the post is archived. If you can repost it here it would be great!
Apologies for the delay, I couldn't find the original photos so I just ripped them from the thread.
Here goes:
I started out with buying a sheet of off-brand Lexan at the local Home improvement store ($4ish and another $5ish for the etching knife tool). I enlarged the bar code in case anyone wants to use the same type as I did. The thickness listed there seems to be the sweet spot between "stops bullets" and "classroom overhead transparency."
Then, using a sharpie, I traced the outline of the License plate and HOV sticker onto the acrylic (I took the excess backing off all but the plate side of the sticker to reduce the amount of plastic showing after mounting but to maintain a tasteful gap between the plate and the sticker).
I used a yard stick I had in my upstairs hallway (yeah, I don't know why either) as a straight edge to keep my scoring straight. I have clamps somewhere... but I couldn't find them this day.
To get the curvy bit I used this nifty cordless multi-tool that I wanted for xmas one year and then let it sit and gather cobwebs (actual cobwebs pictured!). Mounted below is the "jigsaw" attachment. I didn't use this on the straight part for two reasons: 1) Try to cut a straight line with a handheld jigsaw, go ahead, try and 2) I anticipated this plastic melting a bit under the high friction, which it did, even with me going super slowly.
The last bit of work to do before mounting was to drill out holes for the screws to pass through. As it turns out, I lent my cordless drill (w/ bits) to a friend some time ago and he is still in possession of it. CONTINGENCY: Use the nifty multi-tool with the router attachment and the most "drill-like" bit you have. This actually ended up making some pretty decent looking countersunk style holes right up to the point in which the bit punched through and cracked everything.
Be sure to drill both holes and walk all the way back to the car before realizing that your sheet of plastic extends to all 4 holes on the license plate and then repeat the above kludgey method to drill additional holes. Adjust holes as needed, since after all, it IS a router.
Finally, revel in your mastery of improper tools and hare-brained ideas. Mount the license plate (and any frame you might have) on top of the plastic with the HOV sticker and be on your way.
As I stated above, the rigidity seems to be perfect. I can see most of the sticker from the rear camera and even at highway speeds there is no flutter (unless it happens to be at a sympathetic frequency to the frame rate of the camera...).
Let me know if anyone has questions/requests for more detail!
