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What tool to use for cutting into Lexan?

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severdhed:

use a router with a flush trim bit.

remove the lexan, drill the hole in the wood/mdf to the size you want it, then put the lexan back on, and use a flush trim router bit to cut the lexan using the hole in the wood as the guide.

i see you are not sure if it is lexan or plexiglass, i haven't personally used lexan, but i can tell you i've done this alot with plexiglass and it works beautifully, the router cuts through the plexi like a hot knife through butter.

stuckpixel:
I'll second the flush trim bit. Goes right through the plexi without any problems.

Worked with one for the first time this last weekend - it's amazing.

loppydog:
I use a CO2 laser.  You may have one in your area.  You can just draw what you want on a CAD program and cut it out.

fallacy:



FYI i tried using that Scoring tool that he had in the video and could not get it to work. Lexon was to thick and hard for it to cut it seemed like, maybe I was doing something wrong. I finally just took my power saw out to cut through it, you can also use a jig saw.

Ed_McCarron:
If it's really lexan, you could use a dull axe on it and not have to worry about it chipping or shattering.  The stuff is bulletproof.  Literally.  It's what banks make their teller windows out of.

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