Cut Lexan Flush With CP (No Router) ?

[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.

[TalkingOctopus]

I cut my CP and Lexan at the same time with a circular saw.  I think this is probably easiest way to get them to align perfectly.  I know it is not a solution to your problem, but I just thought I'd throw it out there for anyone else starting to make a cp.  Also, I think having your overlay printed before cutting the cp is useful.

[RacerX]

I used my rotary tool with one of those disks.  It more melted the Lexan than anything, but it cut it.  There was some finishing work to be done to get the little bits of melted and hardened Lexan off the edges, though.

[NoOne=NBA=]

The only thing I can think of would be to use paper to get a good outline of the CP, cut the paper out, transfer the outline to the lexan, and then cut/grind/sand the lexan down to that line.

A stationary belt sander with no end guards on it would greatly help though.

[spystyle]

Just rent a router

In my experience using 'alternative' methods has 'alternative' results

[PedroSilva]

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.

Hi,

I've done it all with the dremel plus this atachments/accessories:
It was acrilic instead of lexan, but I believe you can achive same results.

#565 Multipurpose Cutting Kit - Making holes
#409 15/16" Cut-Off Wheel + #402 Mandrel - Cutting
#8175 Alum. Ox. Grinding Stone - Smoth finishing

How to make them perfectcly aligned ?

- Put the plate with with the white protective cover facing up;
- Put the CP on top off it facing down (controls side over the lexan - all the drilling on the CP should be already done on this moment);
- Attach them both secure with several wood clamps;
- Using a ink pen (do not use a pencil cause it will disapear if you pass your hands over it) draw all the holes and the surrounding edges of the CP over the lexan;

Now heres the trick for not breaking it when drilling / cutting:
Use a piece of MDF with 50x50 cm more or less and make a hole on the midle big enought to fit all holes you need to cut.
Put that underneath the lexan on each hole and cut thro it (always start on the midle with a +- 45