Today I made the paper dial for the dial pan. It was drafted with DeltaCad, using numerals from one of the DC resident character sets: "Liberate".
The outer and inner diameters of the dial were drafted exactly to the inner and outer diameters of the inset cut into the dial pan, as measured to the thousandth with a dial caliper. The diameters were indicated on the paper dial with small circular arcs, which guided the dial cutter -- a commercial dial cutter available from clock supply houses. Using this method, you can make very accurate cuts. After cutting, the paper was glued into the recess using Elmer's spray adhesive.
I have also used laquer as a dial protectant with mixed results. The best results were had when the dial paper was given a light coat of laquer from a spray can on both sides before the paper was cut with the dial cutter. The laquer consolidates the paper, making it easier to cut cleanly, and it makes it more resilient to dirt. Spraying lacquer after the dial is glued into the pan is disasterous.
The dial was printed on my Canon BJC-250 color bubble jet printer -- quite an inexpensive printer, but the print quality is excellent. (A laser printer might do a bit better, but I don't own one of those.) I also have an older Canon inkjet printer, and while the quality of printouts is pretty good from this printer, it's not up to dial quality. This dial is small, and it's always a good idea to print several extra copies on the same page. My experience is that this job takes several do's before you get one that's OK.
The paper I use is 100% cotton resumé paper, available from an office supply store. This paper should last longer than common printer paper, without yellowing. It is heavier, and it also has a nice matte finish.
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