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Drilling button holes in Plexi/Lexan?

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Afterburner:

If you have a lot of holes to drill, I'd recommend the hole saw with the plexi sandwhiched between a couple of pieces of 1/4" plywood.

I personally used a spade bit.  If I were going to do it again I'd buy a new one that's nice and sharp.  Some spade bits come with some small prongs at the ends of the paddle that help cut nice, clean holes.

Again, I'd recommend the plywood sandwhich.

Didn't think of using the router with a trim bit.  That would yield good results.

yotsuya:

I had much, much better luck with a Forstner bit than a spade bit. Interestingly enough, I bought a hole saw today to cut holes in a metal panel!

Jakobud:

In my experience, drilling in Lexan is very easy because it's soft.

But Plexi is very hard and brittle.  VERY difficult to drill a hole without cracking it.

Lexan is a lot more expensive than Plexi but well worth it if you are cutting it or drilling holes in it.

RyoriNoTetsujin:

+1 to plunge router, if you have or can get one. Especially for plexi, which I had a hell of a time trying to not chip/crack with any other tool.

kelemvor:

So is Lexan more forgiving and a better all around choice?  I'm open to whatever as long as I can find it somewhere local.

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