Sanding/Smoothing lexan edges

[Silverwind]

I have some rather sharp corners on the edge of my CP from the lexan...

What is the best method to smooth those corners a little.. does sandpaper work well or should I use something else?

[MameFan]

Here's what I did. Took a LOT of elbow grease, but turned out really nicely.

First, I did it with the plastic protective sheet still attached.  Take care if you have already removed it as you may scratch.

First, I used one of those "cheeze grater" style wood planers. NOT the single blade "slicers" rather the rippled, multi-tooth gater ones. Like this one:

http://www.amazon.com/exec/obidos/tg/detail/-/B00002X1ZQ/qid=1047576929/sr=1-1/ref=sr_1_1/102-4630280-4859311?v=glance&s=hi

I basically clamped in the plexiglass in the workbench, then took this planer and went at about a 45 degree angle to the edge, on each edge, on both sides of the edge.  

This results in a tiny "bevel" to the edge.  If you do a pass at about 30 degrees and another at 60 degrees, or just wiggle it back and forth as you plane, you can create a soft curve to it.

Do not press too hard as you'll gouge and chip the surface, but amazingly this tool worked really well.  Note: I was only using "Lucite" not "Lexan" as there are different hardnesses I cannot guarentee this will work on all.  Also, you HAVE to do this with at least 1/5th or 1/4 inch thick stuff. Dont use it on thin 1/20th stuff as you'll just break the thing.


Next, I bought some foam sanding blocks, a coarse, medium, fine (and optionally extra fine) grit ones. (Usualy 2 different grits are on a single block, 2 sides with one, 2 with another).

I started with the coarse and worked thru the fine, sanding the curve of the planed edge off.   I even did 4 corners (it was an Asteroids cocktail project) and it worked good enough to be covered by the clips.

If you stop at fine, you'll have a slightly frosty edge, a bit more smooth than simply sanded glass, but not clear and as smooth as polished glass edges.  Use the extra fine ones to get it clearer/more polished.

This worked for me, and produced a cut-free edge and looks pretty dang nice.

On a 2'x3' piece, all sides sanded, took about 90 minutes to get it "right", minus the corners which were hard.

Good luck!

[Lilwolf]

(can't try here but...)

How about something hardwarish for the main cuts.  Like just a file.

Then, a cloth and toothpaste...  I hear it will work great as a polish.

btw, if you are cutting lexan... take the scrap and play with it... Best way (so you don't ruin your new stuff.

[ErikRuud]

For toothpaste, you need a paste, not a gel.  Tartar control pastes work best.

[bionicbadger]

A dremel with a little sanding drum works.  Then just buff it to finish.

[mpm32]

Flame polish the edges with a propane torch.  You should experiment on scrap to get the right technique.