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Cut Lexan Flush With CP (No Router) ?

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ThePaul:

Hi,

I've spent the better part or the afternoon reading all the old posts relating to cutting lexan.

Basically I'm looking for a method to cut my lexan overlay to match up exactly with my existing MDF CP. I have a jigsaw, circular saw and drimmel avaiable ... but no router.

I just don't see how I will be able to get an exact (flush) cut with any of these tools. Has anyone had success with this setup or am I going to have to find a way convince the wife I need to spend $100 on a router?

Thanks in advance for your time.

SaiNRuB:

Id let you borrow mine if you were close enough.

Any neighbors that owe you a favor?

Xiaou2:


 Maybe you can grab a rotozip type bit to use with your dremel.   Im pretty sure Ive seen them for the smaller dremals..  

   

bdsjake:

I've seen a "router" attachement for dremel and like small rotoary tools.  Can't tell you how good they work, never used the one I have for my dremel., but might do the job for you.

rdagger:

I've had good results cutting Lexan with a sharp box cutter and then sanding with a random orbit sander.  This method is handy on small pieces that are difficult to clamp when routing.

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