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What tool to use for cutting into Lexan?

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Hituro:

So, I have a control panel kit from Mameroom, When I ordered it, I didn't know much about spinner size, so I had ordered the Turbo twist from GGG.  When I got the panel, and saw the spinner I thought, crap!  I should have told them to make the hole a regular button hole!  But alas, I did not, and the hole was small, so I ended up getting a normal spinner from happ.  It works fine, but I would like to use the Turbo Twist.  I also have a layer of Lexan over my Control Panel.  My question is... What's going to be the best way to go about making the hole bigger?  Granted I will have to drill through both the CP AND the Lexan so that they match up.  Is this too hard to do?  And if so, should I just forget about adding the turbo twist?  And what tools should I use?  Would a hole-saw bit work?  I just don't want to drill and end up cracking the lexan.  Because then I'll be the saddest panda because I'll have to attempt to order another lexan overlay, and even then I don't know if Mameroom will do that because they'll only send it with a control panel since they're cut at the same time.  So... what should I do? :P

Mr.Ian:

A local hobby store should carry lexan sissors. They are used to cut/trim Radio Control car body shells.


ChurchOfSolipsism:

I usually use Plexi glass, but I assume the following techniques work on Lexan as well.

I use a hole saw, it works fine. Be careful, though: leave the drill speed way up, but apply only a bit of pressure when you're pushing the drill down so that it takes a lot of time to cut through the lexan.

Many other peple have reported that putting their drill in reverse and slowly "melting" their way through the lexan works well; this way, you're supposed to get really clean edges.

You might consider getting Saint's book, it describes this and many many other basic techniques:

http://www.amazon.com/Project-Arcade-Build-Machine-Wiley/dp/047089153X/ref=sr_1_2?ie=UTF8&qid=1292841203&sr=8-2

I'm sure someone here sells copies of the first edition...

Hituro:

hmm.. maybe I'm using Plexiglas?  How can I tell the difference between Plexi and Lexan?  I thought it was lexan because it looks clear like glass but has some bend to it, like a wobble when you move it.

Thenasty:

wherever you buy the Lexa/Plexi, they have a cutter (Home Depot ex).

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