What tool to use for cutting into Lexan?

[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?

[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).

[severdhed]

use a router with a flush trim bit.

remove the lexan, drill the hole in the wood/mdf to the size you want it, then put the lexan back on, and use a flush trim router bit to cut the lexan using the hole in the wood as the guide.

i see you are not sure if it is lexan or plexiglass, i haven't personally used lexan, but i can tell you i've done this alot with plexiglass and it works beautifully, the router cuts through the plexi like a hot knife through butter.

[stuckpixel]

I'll second the flush trim bit. Goes right through the plexi without any problems.

Worked with one for the first time this last weekend - it's amazing.

[loppydog]

I use a CO2 laser.  You may have one in your area.  You can just draw what you want on a CAD program and cut it out.

[fallacy]

FYI i tried using that Scoring tool that he had in the video and could not get it to work. Lexon was to thick and hard for it to cut it seemed like, maybe I was doing something wrong. I finally just took my power saw out to cut through it, you can also use a jig saw.

[Ed_McCarron]

If it's really lexan, you could use a dull axe on it and not have to worry about it chipping or shattering.  The stuff is bulletproof.  Literally.  It's what banks make their teller windows out of.

[severdhed]

If it's really lexan, you could use a dull axe on it and not have to worry about it chipping or shattering.  The stuff is bulletproof.  Literally.  It's what banks make their teller windows out of.

not all lexan is bulletproof.  sure that is what they make bullet proof glass from, but it is only bullet proof in the proper configuration....you can't buy a sheet of 1/8" thick lexan at lowe's and expect it to stop a bullet.

[markronz]

Another +1 on the flush trim router bit.   I tried the scoring tool as well, and I couldn't get a clean break either.   But once I used the flush trim bit with my router, it cut through it like butter.  Wish I had tried that in the first place!

[Ed_McCarron]

If it's really lexan, you could use a dull axe on it and not have to worry about it chipping or shattering.  The stuff is bulletproof.  Literally.  It's what banks make their teller windows out of.

not all lexan is bulletproof.  sure that is what they make bullet proof glass from, but it is only bullet proof in the proper configuration....you can't buy a sheet of 1/8" thick lexan at lowe's and expect it to stop a bullet.

Thank you, captain obvious.  I was speaking generally.   Of course the thin stuff won't do it.  My point was that it's pretty tough to shatter, which is the main problem with acrylic.  The polycarbonate tends to cold flow instead of breaking into a brazillion pieces.  Treat it like you're machining any other hardwood and you'll be fine.

[Rok]

After a pretty awful experience with both the scoring tool and a drill, I discovered that a flush trim bit cuts through plexi like a hot knife through butter.