Lexan ???

[divemaster127]

hey guys 2 questions
1. how do you cut lexan & with what tool

2. where is the best place to get lexan
thanks
dm

[nostrebor]

's all in the wiki Lexan is Polycarbonate BTW...

http://wiki.arcadecontrols.com/wiki/Plastics

[divemaster127]

thanks a bunch

[AtomSmasher]

This tutorial has a good section on cutting plexiglass and lexan, http://spystyle.arcadecontrols.com/index1.htm

[Mark70]

Save money buy acrylic.  Easy to cut and drill with a router while it's between two pieces of plywood.

[Ed_McCarron]

You can cut lexan just like you cut wood or aluminum.  Its pretty tough, but easy to scratch.

Acrylic is more fragile - if a drill bit grabs kiss it good-bye.  Its tougher to scratch.

Both are pretty routable.

Depends on your preferences.

[ChicagoDave]

I purchasesed a 36"x48" sheet of Lexan at Home Depot for about $60.  I also purchased an acrylic cutting tool.  I used the "sandwich method" (MDF - Lexan - MDF) for drilling the  Lexan and used the tool to trim it to size.

I have attached some pictures of the tool.

[miles2912]

You can cut lexan just like you cut wood or aluminum.  Its pretty tough, but easy to scratch.

Acrylic is more fragile - if a drill bit grabs kiss it good-bye.  Its tougher to scratch.

Both are pretty routable.

Depends on your preferences.

I have been working with Acrylic for my cab and have tested it out quite a bit.  What happens when you are drilling it is when you finally make the hole the acrylic wants to grab the drill bit and ride up or twist causing it to crack.  Once your hole is almost made then slow it down and if the material starts to ride up then stop.  I also do not hold it down securely so when it starts to ride up or twist, I let it.  As far as cutting the stuff I have had excellent results with a router and a pattern bit.  Measure and draw a line. Then clamp a straight edge on the line and follow it with the router.

Don

[psychopanda]

Hmm, I saw that same acrylic cutting tool but neglected to pick it up. Does it cut better than a utility knife?

Lots of people have mentioned this already, but I found it most helpful to drill acrylic by first starting the hole a little ways, then switching the drill to reverse, and then switching back to forward and finishing the hole.  It seems the middle step, running in reverse, helps to warm up the acrylic before you make your final cuts. This method worked really well when using a spade bit to cut holes for joysticks and buttons.

[ChicagoDave]

Hmm, I saw that same acrylic cutting tool but neglected to pick it up. Does it cut better than a utility knife?

Lots of people have mentioned this already, but I found it most helpful to drill acrylic by first starting the hole a little ways, then switching the drill to reverse, and then switching back to forward and finishing the hole.  It seems the middle step, running in reverse, helps to warm up the acrylic before you make your final cuts. This method worked really well when using a spade bit to cut holes for joysticks and buttons.

Yes it does a better job than a utility knife.  It has a small "hook" at the end which actually grabs and strips the Lexan.  A knife would simply cut it without stripping it.  The tool worked great.  Scored 10 times and then cracked the piece off, perfect cut...

[emdkay]

If it's lexan for a marquee you're looking for, I've got 26.0" x 8.0" sheets - two for $9.95 shipped:  http://www.emdkay.net/marquees_custom.html 

[Frosty]

Don't be afraid to get at it with a good router, either.  Works really well.

[MikeDeuce]

Hey, where's the eye protection???