Trim Lexan Before Cutting?

[Ldsfunaz]

I am about to cut my Lexan for my CP-top and I am scared to even look at it wrong.  But I gotta suck it up and just go for it. 

I have a piece of Lexan 48X36, and my CP is 48x24, should i try to score and snap the lexan at about 1" longer than it is supposed to be and then use my flush trip router bit to get it perfect, or should i just use flushtrip bit on the whole 48X36 piece,

thanks
-LDS-

[Bones]

If it is Polycarbonate just go for it with your router.

The overhang in my experience did not affect the the cutting process or results in the slightest. I just took it real slow because I was nervous, not because of any learned technique.







I also did the same with some 8mm thick Lexan with overhang of about 1 foot either side and there was no splintering or other problems.


I don't know the answer to your question if you don't have Polycarbonate/Lexan.

[Ldsfunaz]

It is definitely lexan, so that's not an issue.

My main problem right now is trying to figure out how I am going to support the extra lexan while I am routing it, especially the last few inches.

-LDS-

[Bones]

Mine was not supported in the corners and all was fine. The weight of the router and the clamps stopped it from jumping around.

[Ldsfunaz]

I just wanted to let you know that I just trimmed my lexan successfully with the flush trim bit.

This worked out so well, and was so easy, that I may just have to stick the router bit up my bum.. yes it was that good to me 

-LDS-

[Bones]

All my Lexan was cut with ZERO problems and with no real care taken. It didn't matter if I was routering, drilling, jigsawing or going at it flat out with a spade bit.

I have come to the conclusion that problems only arise when a polycarbonate substitute is used. Debatable comment I anticipate, but this was very much my experience and I am sticking by it.

[rdagger]

I bought a plastic cutter and it is waste of money.  Now I just use a sharp box cutter.  Give the Lexan a dozen scores with the box cutter.  Press hard so it digs deep.  Then sandwich the short side of the Lexan between two 2x4's and clamp them down solid.  Then an even pressure on the long side should give you a clean break.  If you're worried, give yourself an extra 1/2" buffer which you can flush trim with the router.  The longer the cut the more chance of breakage.  Also, if the side you are applying pressure to is too short, this can also cause breakage.