best way to cut 1/8" lexan sheet.

[rdowdy95]

I have a 1/8" thick lexan sheet going to be used for the Marquee.  It is about an inch too big in height.  Maybe an inch and a hlf.  Anyways should I just score it real good with an exacto knife or a box cutter.  What do you guys recommend?  I figure get a straight edge clamped down to it and just start cutting?

[leapinlew]

Your flush trim router bit will go right through it... butta

[fatfingers]

I agree that is the best method, but you should probably cover the lexan with something else before running your router over it.

[ChadTower]

Sandwich it between two pieces of wood, like 1/4" plywood, and cut it that way.

[leapinlew]

and prepare for the best hot plastic shower of your life!

[Shameless plug ahead] Check out page 2 of my showcase build. I discuss the trimming of plexi:
http://forum.arcadecontrols.com/index.php?topic=55021.0

[AlanS17]

and prepare for the best hot plastic shower of your life!

Agreed. Wear a long sleeve shirt that you're not particularly fond of.

[ChadTower]

Sandwiching between pieces of wood reduces that quite a bit.

[Thenasty]

When I bought some Lexan, the store had this CUTTERS for it. You use it like an Exacto knife, you keep scoring the plexi/lexan then when its cut is deep enough, just split it.  Dunno what it was called.

[AlanS17]

When I bought some Lexan, the store had this CUTTERS for it. You use it like an Exacto knife, you keep scoring the plexi/lexan then when its cut is deep enough, just split it.  Dunno what it was called.

Home Depot and Lowe's can do this to get it down to a basic size. It's perfect if all you need is a square or a rectangle (ie. monitor glass). Anything with a rounded edge needs to be done on your own, though (ei. control panel). I used my jigsaw and it worked fine. It needed some sanding, but my jigsaw skills far surpass my router skills.

... but neither compare to my bow hunting skills or my numchuck skills.

[ChadTower]

Those chucks sure get num.

You can score out curves, it's just harder and takes longer.  May be easier for someone without the tool skills.

[sealslayer]

I used a blade that has a hook shape to it, it scores so deep on 2mm plexi that you can snap after just one cut.
As long as you have a straight edge to score along it will work great.

[AtomSmasher]

router and flush trim bit is the easiest way, you don't need to sandwich it between wood, but it couldn't hurt.

[jcrouse]

Use a router bit in this:

[NiteWalker]

Use a flush trim bit and a straight piece of wood or MDF. No need to make a wood sandwich. Lexan WILL NOT under ANY circumstances crack. The table saw also works fine. I rough cut on the table saw and then use a flush trim bit with my control panel templates to make an exact copy.

The score and snap methods don't work as well with Lexan. It usually leaves a rough edge that needs to be sanded. The router method is cut and you're done.