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nervous about cutting my plexi...advice? (yes i have searched)

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andrewonawall:

So the scoring and breaking off the table edge method, that won't work for rounded edges, will it?

Also, for button holes. I have heard that running a hole saw in reverse will melt a nice clean hole with no cracking. Does this really work well?

abrannan:

Well, since everyone else is chiming in, here's what I did.

1. Use the x-acto knife/box cutter method to cut the general shape of my plexi (add about 1/2"-1" in each dimension to give you some "fudge" room)

2. sandwich and clamp the plexi between the pre-drilled MDF top and antoehr piece of scrap wood (MDF, plywood, whatever)

3. turn the whole assembly over, so the pre-drilled MDF control panel is on top

4. Using my forstner bit at high speed in my drill, drill out the holes in the plexi through the holes in the MDF control panel.  This gives you holes drilled EXACTLY where you need them.

5. remove the scrap wood backing and turn the assembly back over, now you have the plexi on top of the Control panel.

6. Use a couple of buttons through a few of the holes to "clamp" the plexi to the control panel.

7. Using the flush trim bit in my router, clean up the outside edges of the plexi top.

8. If needed, run the flush trin bit inside the holes to clean them up as well, just move the button holders as needed to give you room to work.  

That method gave me no cracks, no scratches, and most importantly, no problems.



spystyle:


--- Quote from: TalkingOctopus on April 29, 2004, 09:43:13 am ---I wouldn't cut it with a jig saw either.  I think that it would probably crack.  However, you could try a practice cut on a scrap piece to make sure.  I cut my lexan with a circular saw.  When I tried a jig saw on a scrap piece, it cracked!

--- End quote ---

I always cut my plexi on my table saw, it works like a dream.

I adjust the hieght of the blade so it is flush with the hieght of the plexi (1/8")

In other words I cut it on the table saw with the blade only 1/8" high

works flawlessly

then I do the rest of the cutting with a router

I've never cracked a piece with this method, just keep allot of pressure on the plexi so it doesn't vibrate

(p.s. if you have to drill it use regular drill bits and holesaws in reverse @ your drill's highest speed)

Dig it?
Craig


hulkster:

well ive since made progress....and decided not to even use plexi or lexan or any covering for that matter.  im buying art form classicarcadegrafix.com and its going to be sealed with a really tough vinyl so that it wont need any covering.  its a little pricey, but worth it in my opinion.

Tahnok:

Hmm... I remember back when I was trying to cut some plexi for the window on my computer I used a jigsaw without any problems. I left the normal covering over the sheet of plexiglass and also taped both sides of my cut line with masking tape. The cut has no cracking, splintering or spidering. The only problem I have ever heard of from people cutting plexiglass was when someone tried going very quickly and melted their blade right into the plastic.

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