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Acrylic drilling help

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monkey puzzle:
Is it possible to use hole saws for the holes? I have a large hole saw for my trackball. Should I risk using this?

upprc04:

--- Quote from: monkey puzzle on October 26, 2011, 01:50:24 pm ---Is it possible to use hole saws for the holes? I have a large hole saw for my trackball. Should I risk using this?


--- End quote ---

I had great success drilling a small hole and used a router w/ flush trim bit to cut the holes for buttons/joysticks to the same size as the control panel. 

Turnarcades:
I hate hole saws in general, as to get a clean cut you've got to go in dead level. Adjustable hole saws are good as the cutting tips cut their own path without much resistance, whereas the load on standard hole saws need to be even and at high speed to cut properly. Most of the techniques listed above are all good, though of course we've had lots of experience cutting with space bits by hand in the method mentioned earlier, so will stick with that.

On a similar note, I am toying with the idea of creating an incremental video series detailing one of our builds from start to finish to help kit customers and forum novices, what do you think?

yotsuya:
Videos sound like a great idea.

I've had nothing but success using a Forstner bit to cut plexi.

ChadTower:
I've used holesaws.  It does come out a little shredded but you can sand that off so long as you don't walk with the saw.

I have found that rather than trying to cut a perfect hole I have better results cutting a hole that is a little too small.  Then I use a circular sanding bit on a Dremel and sand it to the right size.  That allows you to customize the hole as you need and clean up the edges at the same time.

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