Drilling button holes in Plexi/Lexan?

[kelemvor]

Howdy

So, I've looked online but didn't really find anything definitive.  For those that have a plexi/lexan top to your CP, how did you drill the holes for the buttons and jotsticks?  I have a 1-1/8" spade bit that I thought maybe I could drill a small pilot hole and then use that and just go real slow or even in reverse.  I've also seen people mention using hole saw bits, but I don't have the right size so I'd have to go buy one.

I contacted a local glass shop and they can cut me a piece of lexan that's the right size for my CP for like $20, but then they want $11 for each hole which is completely obscene since that would cost more than the rest of my entire cabinet.

So, just looking for any advice.

Thanks.

[Nephasth]

Don't use the spade bit. Go buy a hole saw.

[wp34]

I didn't have very good luck with a Forstner bit. I was going to recommend a spade bit.
 

[Louis Tully]

.

[javeryh]

Use a single fluted drill bit to make a clean pilot hole (it won't crack the plexi) and then clean it up with your router and a flush trimming bit.  It's a lot easier than it sounds.

[Knievel]

Router is the way to go for sure. You can get a plunge bit that will allow you to drill though and then route out the hole.

If you don't have one I would recommend using Lexan instead of Plexi with drill bits.
It's a softer material and should drill easier, and without cracking.

[BobA]

+1 for the router and trim bit.

[kelemvor]

Do I need to run the router on a slow speed or can I let it crank?

[BobA]

Run it at regular speed and the plexi will cut like butter.

[monkey puzzle]

I used a hole saw for all my button holes with no problem. Have the drill on a high speed, but apply very little pressure. If you want to be cautious sandwich the plexi between 2 peices of plywood and clamp together. Take your time and don't try to rush the drilling. Do a few practice holes first on spare plexi.

[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.

[yaksplat]

Forstner bit for pilot holes and then use a router with a flush bit to make them perfect.

[kahlid74]

Having worked with both Plexi and Lexan I will never go back to Plexi, even for the extra few bucks Lexan is.  It's so much easier to work with.

I love forstner bits but when it comes to cutting Plexi/Lexan, the best luck I've had is with hole saw and the Sandwhich method others have mentioned here.  Always worked with no issues.

I love the router/trim idea but to make the whole perfectly round, you'll need to use a bit.  I'm not a fan of spade bits for anything.

[kelemvor]

I already have the base of the CP built and such, just looking to add the acrylic on top of it.  I guess I'll get some Lexan and try our my router (if I can find it).

[Knievel]

This one bit will allow you plunge(drill) through and then route out the hole..
http://www.leevalley.com/US/wood/page.aspx?p=30184&cat=1,46168,46171\

If you are going to use a router then I would buy plexi. It won't scratch as easily as Lexan and it's cheaper.

If the plexi has a protective covering you can't see through just clamp it to your CP and shine a flashlight up through the holes.
Then you can mark their locations with a sharpie up on top of the plexi and plunge away.