cut plexiglass

[Keith O]

I've seen the recommendations for cutting holes in plexi but what about cutting the outside edge? Will a router do a decent job or will that cause too much heat. I've tried using my jig saw but the edges look really bad.

[ArcadeFX]

They make a special router bit for plexi.  A router makes the best cut with this bit.  Very clean.

[Elaundar]

I have very little experience working with plexiglass, but this is what I did:

On the square cuts, I let home-depo score and snap the plexiglass to approximately the correct size.  As could be predicted, it was a good 1/4th inch too big for my cab.  I had already destroyed a piece of plexiglass by scoring it badly, so I decided to try something creative...

I mounted the plexi between 2 pieces of scrap wood with the plexiglass sticking out just the amount that was undercut.  I clamped the 2 boards and glass together very tightly.  Then, I used my belt sander to sand the plexiglass to the exact shape.  This allowed me to make *very* precise cuts with absolutely no hairline cracks.  

I wouldn't try this on more than 1/4th an inch at a time, and even then, work at it slowly.  

[SirPoonga]

I used a dremel for edges and a GOOD hole drill bit with drill for holes..

[slug54]

You can buy a  plex knife at most home centers.
Just score it and then snap it.
                   Slug54

[matt]

We cut it all the time in the shop, try a straight router bit (carbide) with bearing, like a 1/2 straight bit with 1/2 ball bearing guide. use a straight edge or pattern underneath that the plexi glass is clamped to and have at it, no problems at all and a crisp edge, leave the plastic film on while doing this (until your done working with it) you can cut it on a table saw as well but the edges might end up with small chips. a rotary cutter like a router or dremel or roto-zip is taking the chip out sideways eliminating the pulling down action of a conventional saw (aka chipping) so any of those will work, or snapping it with a plexi scoring tool. Hole saws going slow or spade bits with long outside spurs for holes work well, just go slow and let the plexi keep cool to prevent melting it. Best of Luck Matt

[klutzo]

Well... just had my first Experience with Plexi...

I pretty much nicked the hell out of all my Joystick screw holes... =< BOO... I have to counter sink them anyways, so maybe they'll still turn out.

My Button holes are quite close together, and I managed to create a crack from button 4 and 5.  DOHDOHDOH!

Yes.. everybody, big hint.. GO SLOW.. take your time.

One other thing that seemed to help.. if using HOle cutters (Or SPade bits) start a small drill hole first, then run the spade bit in reverse.  This will score out the hole for you.  Then FLIP the plexi over, and score the other side.  I'm sure this saved me much grief afterwords.

Oh well, live and learn.

[darkmanx]

ok, i am a little confused. is lexan a type of plexiglass or just another similar material? i have heard its easier to work with than regular plexi.

[ErikRuud]

Plexigalss and lexan are different.

[darkmanx]

ok, sounds like im gonna go with lexan...hopefully the home depot here carries it. for some reason all the home improvement stores here in WI suck. people at one store took 30 min to find me a t-square!  

[Jeremy Cline]

I just made a template and took it too a glass/plexi shop.  They drilled and cut it for just a few bucks over the cost of the plexi alone.  Totally clean and professional.

Jeremy Cline