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cutting pexiglass correctly?

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Member - Posts: 2
Member spacespace
Joined: October 29, 2005
Location: United States
Posted: November 09, 2005 at 4:16 PM / IP Logged  
ok i need to know how to cut say 1/4 in and 1/8 in pexiglass and say 1/16 to 1/32 sheet metal properly because im sure the correct tool is about the only one to use without it break and not conforming correctly so help with that would be appreciated im going to use this to mod my computer but the knowlegde id like to have for an amp rack i plan to make in the future out of pexi using neon lighting etc... so your know ledge is muy apreciated! thanx
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Member - Posts: 5
Member spacespace
Joined: November 09, 2005
Location: United States
Posted: November 09, 2005 at 9:10 PM / IP Logged  
Cut plexi with a jigsaw and a router. Make a template out of MDF, cut with a plactic blade in your jigsaw, then flush trim the rough cut plexi to the template. Don't use the same bit you use to cut wood with to make as clean a cut as possible. If my rough cut line is more than the width of the router bit(I use a 1/2" shank) I'll go around the piece ,attached to the template with 2 sided tape, with a bearing thats 1/4" bigger than the shaft, then flush it with my finishing bit.
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Member - Posts: 31
Member spacespace
Joined: July 10, 2005
Location: United States
Posted: November 11, 2005 at 2:05 AM / IP Logged  
I just use the Dremel with a dimond plated cut-off wheel.
When you do things right, people won't realize you've done anything at all.
Copper - Posts: 141
Copper spacespace
Joined: December 01, 2004
Location: United States
Posted: November 26, 2005 at 5:38 PM / IP Logged  
What if you use a big ruler, clamp it down & deeply score a line along the ruler. Then just bend the plexi at the scored line so it can crack. I've never tried cutting plexi, but if i had to, I would try this befor eanything.
note: this is only to cut straight lines.   
Silver - Posts: 394
Silver spacespace
Joined: October 29, 2005
Location: United States
Posted: November 26, 2005 at 11:43 PM / IP Logged  
i just tried scoring and it did not work to well. it splintered for plexi that the end are not showing i use a skill saw with a 40 tooth blade. and it works fine.
Member - Posts: 10
Member spacespace
Joined: October 30, 2005
Location: United States
Posted: November 27, 2005 at 2:07 AM / IP Logged  
leave it to me to suggest a lazer for true detail work....
With respect to scoring, it works, on sheets, I have had it work on 1/8" and other small stuff but past that it. Its futile not to mention dangerous...I have enough nicks scrapes and razor knife accidents on the job, on my own and from midnight fabrication marathons without trying to saw through acrylic with one. for holes, a hole saw works ok run in reverse, literally melting thought the acrylic. Plastic drill bits are also a useful investment if you plan to do allot of acrylic fabrication. For a PC modder the best tools are likely the dremell, the die grinder for the better equipped, the nibbler, a basic power drill, and a nibbler, the nibbler is an invaluable tool to get small holes and used to be a common PC modder tool to do big windows on a low budget, just wear gloves or get big blisters, you can get very smooth results with hardly any filling.
Silver - Posts: 751
Silver spacespace
Joined: September 09, 2004
Posted: November 28, 2005 at 2:03 PM / IP Logged  

I just bought a nibbler to do sheet metal work for shaving door handles. It is amazing. I just cant get mine to cut intricate shapes because of the back side of it. So I just use sheet metal snips to do that. About $20 bucks at your local air and heating supply store.

Learning the trade one fiberglass creation at a time!
Platinum - Posts: 5,041
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Joined: December 23, 2002
Location: Arizona, United States
Posted: November 28, 2005 at 2:16 PM / IP Logged  
Best way for installers is the router. Make a template out of wood, double sided tape it to the plexi, and then run the router to the outside of it. You can do it with a jig saw but make sure that you have a fine toothed blade in it and take your time.
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Platinum - Posts: 7,056
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Joined: December 14, 2004
Location: Isle Of Man
Posted: November 28, 2005 at 3:39 PM / IP Logged  
When your done....try taking a scrap piece, and get out your propane torch. Flame polish the edges....looks good. test it....not too hot the stuff melts and burns.cutting pexiglass correctly? - Last Post -- posted image.
Silver - Posts: 206
Silver spacespace
Joined: November 01, 2003
Location: United States
Posted: December 06, 2005 at 11:32 PM / IP Logged  
My best recommendation is the router, and if you have the balls and are good enough a jig saw with a high tooth count blade, like everyone else mentioned. As well as for clean up, get some 220 grit give it all a nice sand, then take it to your buffer and get some good polish and polish it up, then if you have to, go up to 400 and polish again. Comes out CRYSTAL clear. Good luck. If you want to be a lazy PC modder(like myself) by yourself a prefab plexi case. They are only like $30.00 now. Good luck!
Duke Duke

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