Best way to TRIM a plexiglass bezel

[Trig]

I purchased a new display for my cabinet.  It sits in a slightly different spot than my old display and plexiglass bezel doesn't quite fit.  The bezel is just a flat sheet of plexiglass painted black that sits in front of the monitor.  I've read multiple threads and sites showing how to make a straight cut by scoring, but I need to trim less than 1/8'' off each side.  It doesn't seem like there would be enough leverage to snap this thin of a piece.  I thought about using a dremel with a cut off wheel, but many people have posted this will melt the plexi.

I'm looking for suggestions on how to trim the sides down to leave a nice edge.

Thanks in advance.

[garnerb350]

try this on a piece of scrap....but I would try the dremel sander bit (low speed) before using a cutting wheel.

[javeryh]

Router. Pattern (or flush) bit.  Straight edge.  Clamps.

[xtravbx]

That will definitely melt the plexiglass - i've made that mistake.

1/8th of an inch is so small, it's going to be very difficult to make that accurate cut.

You're going to lay the plexi flat on a smooth surface so as not to scratch it. Hold a straight edge that's long enough to mark the entire cut.

Use an x-acto to score the cut. Score it extremely well.

What saws do you have available to you? A bandsaw? Tablesaw?

[Ginsu Victim]

If all else fails...

straight edge clamped down
score, score, score, score, score, score, score, score.....
do it until you can snap it cleanly with pliers.

Since you DO have a router, don't listen to this.

[javeryh]

Seriously, a router, a pattern bit and a straight edge will do the trick - it cuts through Plexiglas like butter and you can make highly accurate cuts.  Obviously test it on some scrap first but I've done this many times.   

[severdhed]

i agree..use a router with a flush trim bit..just clamp it to a piece of MDF or somethign with a nice straight edge and use the MDF as a guide..works beautifully...as far as i'm concerned..it is the only way to cut plexiglass.

[MrMojoZ]

I've used a router to shave by the mm on plexi, works great.

[Trig]

Thanks for the suggestions.

I've got a router, but unfortunately I don't believe I have the recommended pattern trim bit.  I think I'll try the dremel sanding drum with two straight edges secured to either side and also scoring on a test piece of plexi and see how it goes.

[lordtodd75]

router and guide all the way, i did my cp overlay that way and the cuts are flawless.

[javeryh]

Thanks for the suggestions.

I've got a router, but unfortunately I don't believe I have the recommended pattern trim bit.  I think I'll try the dremel sanding drum with two straight edges secured to either side and also scoring on a test piece of plexi and see how it goes.

A pattern or flush trimming bit is only like $20 - surely the cost of replacing the Plexiglas you may ruin trying to sand it or snapping it off.   

Plus, these are essential bits in the workshop!   

[Bender]

Thanks for the suggestions.

I've got a router, but unfortunately I don't believe I have the recommended pattern trim bit.  I think I'll try the dremel sanding drum with two straight edges secured to either side and also scoring on a test piece of plexi and see how it goes.

A pattern or flush trimming bit is only like $20 - surely the cost of replacing the Plexiglas you may ruin trying to sand it or snapping it off.  

Plus, these are essential bits in the workshop!  

Absolutely, can't live without one! If you have a router you MUST get one, flush trim is 80% of what I do with mine

PS I just trimmed the plexi for my marquee and bezel with it, just clamp a straight edge and go, done in 30 sec.

[TOK]

Thanks for the suggestions.

I've got a router, but unfortunately I don't believe I have the recommended pattern trim bit.  I think I'll try the dremel sanding drum with two straight edges secured to either side and also scoring on a test piece of plexi and see how it goes.

The two straight edges clamped here might save you, but I agree with the rotary tool melting the plastic. It just does too small of an area and makes a lot of heat.

Before I had a router, I used a random orbital sander to do what you're doing. It still took a bit of work to get the sides smooth and flat.

[Franco B]

Thanks for the suggestions.

I've got a router, but unfortunately I don't believe I have the recommended pattern trim bit.  I think I'll try the dremel sanding drum with two straight edges secured to either side and also scoring on a test piece of plexi and see how it goes.

A pattern or flush trimming bit is only like $20 - surely the cost of replacing the Plexiglas you may ruin trying to sand it or snapping it off.  

Plus, these are essential bits in the workshop!  

Absolutely, can't live without one! If you have a router you MUST get one, flush trim is 80% of what I do with mine

PS I just trimmed the plexi for my marquee and bezel with it, just clamp a straight edge and go, done in 30 sec.

/\ What those guys said

[Jack Burton]

A plain file or sandpaper won't work?  Is there something about plexiglass that makes it hard to sand or file down? 

[garnerb350]

I've read multiple threads and sites showing how to make a straight cut by scoring, but I need to trim less than 1/8'' off each side.  It doesn't seem like there would be enough leverage to snap this thin of a piece.  I thought about using a dremel with a cut off wheel, but many people have posted this will melt the plexi.

I'm looking for suggestions on how to trim the sides down to leave a nice edge.

Thanks in advance.

Trig ....with it being less than 1/8...a dremel sander will do...

I had to do the same exact thing last night.

Now if you are trimming more...YES use a router....

I took a flush trim bit...router ....two pieces of straight board...clamped the pexi between the wood peices ( keep them flush...with the pexi poking out ) and ran the router thru....

I had a little of trim left to do and I just took my dremel and sanded what I wanted ...it was hair line trim....

But just use common sense....yeah pexi heats up and melts...IF YOU KEEP THE SANDER ON IT for long periods... also make sure you are sanding level....

But just use common sense...Be gentle with the pexi glass like you would your wife....not like a groupie at a Lamb of God Bus Backstage pass....

[Trig]

Thanks to all who responded.  I am still following this thread, but my new daughter decided to arrive 4 weeks early and I've been a bit busy.

[severdhed]

congratulations!!!

[garnerb350]

Congrats bro....I found out my wife is 5 weeks...I AM Glad I got mine done...