Lexan Cutting? CPO protection

[Taborious]

Getting ready to start constructing my CP. I have the wood and the Lexan but I was wondering what is the best way to cut the Lexan? I was going to sandwich it between 2 peices of MDF but I'm wondering is a circular saw my best bet and any suggestion on teeth count for the blade? Do I need to lubricate???

[IMMark]

They make a circular saw blade specific for plexi/lexan, can't remember the brand.  Might be able to use other blades too, probably the higher number of teeth the better.

[nostrebor]

I cut it on a table saw with a 60 tooth blade if I am using a "circular Saw" IMHO the best way to cut it is with a router and a pattern bit.

[rdagger]

The easiest way to make straight cuts in Lexan is to use a utility knife.

[Taborious]

Is there a specific type router bit I should be looking for?

[Sasquatch!]

Is there a specific type router bit I should be looking for?

I used a flush trimming bit.  See here..

[DreamWeb]

What about for the rounded edges of lexan/plexi?  Would you just sand it down (is this possible?  I've never worked with it before)

Thanks guys.

[walls83]

sanding will leave scratchs.  A diff. router bit will round the edges.

[Taborious]

I'll give the razor knife and router bit a shot, I'll post pics after the fact.

I've worked with MDF before but I have just cut it with the blade that came with the saw. Does anyone know what the best teeth count blade is for cutting MDF. Mine is probably about 34 (7 1/4)

[nostrebor]

I'll give the razor knife and router bit a shot, I'll post pics after the fact.

I've worked with MDF before but I have just cut it with the blade that came with the saw. Does anyone know what the best teeth count blade is for cutting MDF. Mine is probably about 34 (7 1/4)

Mdf will cut fine with that tooth count. It (MDF) is hard on blades ao carbide tipped blades are best. For smooth cuts use a "saw board" as a guide wherever you can.

Also use dust masks when cutting MDF. It is nasty stuff, will make lots of fine dust, and is very irritating to the eyes nose and throat.

Dave.

Edit: added saw board linkage below.

http://www.benchnotes.com/Skillsaw%20Guide/skillsaw_cutting_guide_boa.htm

[GGKoul]

If you do use a Knife to cut the Lexan.. take your time and remember to always scrap on the same spot... as you can easily side off the line and make another scratch line in the lexan.

[rosborn]

I second Sasquatch on the use of the flush-trimming bit for this.

[markrvp]

For my control panel I rough cut the Lexan with a Band Saw and then screwed it to the CP top which had already been drilled for Joystick and Button Holes.  I used a 3/8" laminate router bit to make a perfect cut around the edge.  I then drilled 3/8" pilot holes through the Lexan (where the button and Joystick holes were) and ran the router bit through these for perfect holes in the Lexan.  See image below.

For smooth cuts in MDF and particle board, use a blade with as many teeth as possible.  Same principle as wood cross cuts.  There is less tear.  This Freud blade is the best in my opinion.  It is expensive, so if you won't need a saw blade after this project, you can get a cheaper knockoff.

[DreamWeb]

Does all of this also apply to Plexiglass?  I know they're not quite same thing..  I was just wondering if plexi and lexan were pretty much interchangeable around these parts.

d.

[nostrebor]

Does all of this also apply to Plexiglass?  I know they're not quite same thing..  I was just wondering if plexi and lexan were pretty much interchangeable around these parts.

d.

Yes.

[rdagger]

What about for the rounded edges of lexan/plexi?