I've never assembled plaques and plates, but I make templates all the time on my laser to help align other things that I assemble. It seems that if you will be making a lot of these it would be worth making a template.
If you use the laser to cut a piece of acrylic the size and shape of the plaque, and then in the center of that you cut out a rectangle that is 5.75 x 7.75, you can lay that template on the plaque and then drop the larger plate through the hole in the center to align it to the plaque. You could glue a couple of scrap strips of acrylic to the sides of the template that rest against the 4 sides of the plaque so the template is held in place to the plaque and won't move while dropping the plate through it.
A second piece of acrylic can be cut that is 5.75 x 7.75 on the outside and has a 5.5 x 7.5 hole cut in it. That leaves an 1/8" wall on the 4 sides. After placing the larger plate through the first template, the second template can be placed into the hole of the first one, on top of the larger plate. Then the smaller plate can be dropped into the hole in the second template. That aligns the smaller plate to the larger one.
After pressing on the plates simply lift off the templates. |