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Plexi drilling problem

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iscariot:
I've read two different opinions on drilling plexi here.  So far I've tried both super-fast and ultra slow with no luck.  No matter what I do the plastic cracks.  Can someone give me some advice?

severdhed:
here is another thread on the subject. 

http://forum.arcadecontrols.com/index.php?topic=89334.0


i too had the problems with it cracking.  i ended up using a router to drill all of my holes, and it worked great.

thecheat:
I just drilled my plexi this past weekend. I glued my hole pattern to it, clamped it to my c/p board, and used a 1 1/8" hole saw to drill. Never had a problem at all. I started with a (small) drill press but I couldn't get most of the holes because it wasn't big enough to reach towards the inside of my panel. Put the still clamped panel in a vice with a couple scrap wood blocks in front of the jaws and drilled with a power drill and the hole saw.

I wish I had a forstner bit, the hole saw would load up with the cores and I would have to remove them every time I drilled.

ctozzi:
try lexan it's more $$$ but will never ever crack.

FrizzleFried:
Plexi is a ---smurfette--- to drill.   GO SLOW...use the weight of the drill only to push through...

Lexan is MUCH MUCH easier to work with.

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