Plexi vs the Router

[psychopanda]

Discovered that I have a 1/16" overhang of plexi on one side of my cp. I previously used a dremel tool to cut the plexi, but recently the dremel died.

I was thinking about trying to remove the excess with a router, but I think that the plexi will crack once the router bit comes in contact. Has anyone had any luck using a router to trim/cut plexiglass?

[AtomSmasher]

Has anyone had any luck using a router to trim/cut plexiglass?

IMO thats the best way to cut plexi, using a flush trim bit.

[leapinlew]

Has anyone had any luck using a router to trim/cut plexiglass?

IMO thats the best way to cut plexi, using a flush trim bit.

I agree. I recently cut plexi using the same method. Just be sure to clamp the plexi down well. Here is a picture of me cutting MDF with a flush trim router bit.

[MYX]

I used a router as well. I even used it for my button holes. Worked great. Make sure your bits are new and/or sharp.

[psychopanda]

Thanks guys, that bolsters my spirits!

I'll have to give it a try. Does the router leave sharp edges on the plexil? Most of my plexi edges are surrounded/hidden by wood because I couldn't get them very smooth.

[leapinlew]

smoooooove!

[Tahnok]

The edges aren't sharp unless you point them. I've cut myself on scrap pieces a few times because I wasn't being carefull. You shouldn't run into any points like that on the actual cabinet though. Not only that, but router cut edges don't need to be polished.

[MYX]

On the edges of my CP, I used a 1/8 round over (after I did the flush cut). I talked to Pixelhugger about his bullnose. He gave me suggestions and I embelished on his advice. He said to sand with super high sand count (he recomended 600).

I could not find that high, the highest I got was 400. Wet Sanded, the edge. My sander came with a cleaning pad it is kind of like a cloth brillo pad. I did that all the way around. then I used a dremmil with the cloth wheel and polish compount all the way around. Then finished it with novous 2. It is nearly a lens. There is a definate optical curve.

[Ayrk]

One option that my father used when he made wind chimes was to use a propane torch on the plexiglass. It made the edges very round and smooth and the clear plexiglass stayed clear.

I'd do a few tests on scrap pieces first, though.

[psychopanda]

On the edges of my CP, I used a 1/8 round over (after I did the flush cut). I talked to Pixelhugger about his bullnose. He gave me suggestions and I embelished on his advice. He said to sand with super high sand count (he recomended 600).

I could not find that high, the highest I got was 400. Wet Sanded, the edge. My sander came with a cleaning pad it is kind of like a cloth brillo pad. I did that all the way around. then I used a dremmil with the cloth wheel and polish compount all the way around. Then finished it with novous 2. It is nearly a lens. There is a definate optical curve.

That sounds cool! Any pics of the end result?

Don't know how much work I'll put into the edges because I placed my t-molding so that it has a small lip to cover the plexi on the cp once I get it cut down to size. But I'll probably experiment just to see what happens.

[psychopanda]

Well, as the rest of you stated, routers work very well for cutting plexi. I don't think I'll ever use a dremel tool for that job again.

I used my flush trim router bit for the most part and then went over the top edges with a roundover bit. The only real mistake was that I ran the router directly on top of the plexi when I used the roundover bit and it left some scratches on the plexi. I think I can cover those scratches up with some Novus 2 though, because they are barely noticeable.

[DrewKaree]

For anyone else who ever reads this (or remembers this), simply throw some masking tape on the base of whatever you're using before putting it on your plexi.  Problem solved UNLESS you're not at all tidy and decide to lift whatever tool you're using and set it back down without cleaning off the surface you're about to rest whatever tool you're using and set it on some plastic shavings.  Nicest way to ensure gouging the snot out of it.

They also make 2" masking tape for those of you unfamiliar with anything other than the ³/₄" stuff.  Cover, and trim away any tape from the openings.