Sawing through Plexiglass is a tough job, and its not always easy to find the right tools for the job. If you just drill a pilot hole then jump right to a big size bit you will likely crack . Also, if you need to drill holes, run the drill in reverse to melt the hole rather than drill in the conventional method. A saw is the right tool for this job. Having said that, the best way to do it is to use a table saw or circular saw with a fine teethed blade. Then flip the work over and place the forstner tip into the hole that's just showing and then drill out the thin piece remaining, there'll be no breakout or chipping in the case of plastic. Apr 7, 2008. Simply cutting through plexiglass is one thing. Im sure you dont have one lying around the house. Therefore, be careful while handling Lexan and use protective gear. 7) Make sure to wear safety goggles while cutting. Posted: 3/3/2023 3:10:29 PM EDT [#45] Cut it all the time with table saw. Start the process with 120- or 180-grit waterproof sandpaper, in combination with a wood or rubber sanding block. Find a place, any place, that can cut it for you. 3.1 Choose the Right Type of Hole Saw and Hole Saw Arbor. You can use a table saw, circular hand saw, jig saw, or band saw to cut Lexan. Brand names include Lucite, Vitroflex, Perspex, Acrylex and many others. Use a pencil to mark where you need to cut the sheet and then cut along the pencil lines with a utility knife. A few ways to cut different thickness sheets.Another Know How Now video you might like: Cut Lexan Polycarbonate Sheet With Circular Sawhttps://youtu.be/XydMn2he1OcThere are hundreds of videos at Know How Now, subscribe so you can always find the channel. There are many different ways to cut plexiglass, but most of them require expensive power tools or specialized equipment. Place the sheet over a hard edge with groove-side up. Lexan is a common material used in many home or construction projects. Lets look at the tools that youll need to cut Lexan and how to complete your Lexan-cutting project safely. Coarse-tooth saws should be used for cutting Plexiglas acrylic sheet. Its also best to operate your saw at its low or medium speed. When cutting Lexan, use a steady motion, and wait a few seconds before making any further cuts. Whatever your purpose for using this versatile material, you now know how to cut Lexan effectively. The best way to avoid chipping or cracking the lexan is to use a softer material, such as rubber or foam, to protect it. Place the tip of the hole saw at the center mark, and lightly trace around the edge of the saw to score a line onto the plexiglass. Lexan sheets can become quite hot while cutting due to friction. This will give you a smooth cut.. Its a very strong material. Cutting Polycarbonate Using a Table Saw. Using a marker to draw the path that you want to cut on both sides of the protective film. Use a permanent marker to mark your measurements on the Lexan. Use a hole saw run it in reverse until the hole is started then go forward this will prevent the hole saw from walking. And wherever theres friction, there is heat which is bad for the Lexan since it can melt. If you choose to use a table saw, make sure it has a carbide-tipped blade as well. Shop products from small business brands sold in Amazons store. It takes a special drill bit to properly drill through Plexiglas, Lucite, Acrylite, or Perspex acrylic sheet. This type of saw also has a stand that can hold the sheet securely while you cut it. Benefits of using a jigsaw when making cuts on Plexiglass. Additional comment actions. 6) Follow the manufacturers instructions for your power tool. While it is a common material, many people struggle to learn how to cut Lexan. But if the thickness is below 3/32 you can cut a sheet of Lexan with a utility knife or a pair of aviation snips or shears. Place the blade and set the cutting speed to at least 2500 RPM. We might receive commissions (AT NO EXTRA COST TO YOU) if you end up buying a product using our links! Running the blade too fast or too slow can damage the Lexan sheet. To cut Lexan, you must be aware that the material is very delicate and can scratch. Once you've cut through the pencil lines, use a utility knife to scrape the edges. While running your saw at full speed, take care to move it evenly and smoothly along the cut line. Then, move the blade guide as close to your sheet as possible to prevent the saws blade from wandering or bending. This Processing Guide (PDF) has details on the sorts of blades you should use. Spyder's Tungsten Carbide-Tipped (TCT) hole saws cut more materials up to 5x faster and make up to 10x more cuts lasting longer than conventional bi-metal hole saws. It's not as easy as I. Time to set up the router. Friction produces heat, which can melt the Lexan. Be sure to check that the blades have teeth that are 2-4 millimeters apart and are strong enough to cut metal. cack01 Member Joined Mar 7, 2002 Location San diego or UC Davis Jun 8, 2004 #9 document.getElementById( "ak_js_1" ).setAttribute( "value", ( new Date() ).getTime() ); This site is a participant in the Amazon Services LLC Associates Program, an affiliate advertising program designed to provide a means for sites to earn advertising fees by advertising and linking to Amazon.com. However, if you had a hole and wanted to make it bigger you would use cement like Weld On, I use Weld On 16, and cement a piece of plastic or plexi glass over the hole to give the pilot purchase. Use ruler to be as precise as possible. Additional comment actions. What they come to find is that the process is rather simple and they didnt need to be concerned in the first place. Place the piece you wish to cut over the edge. 4 of 4 products in category "T-Shank Jig Saw Blades for Plastic" found Ascending (A-Z) Descending (Z-A) 3 pc. The normal 118* or 135* metal drills can break sheet plastics unless used very slowly far from an edge. What Kind of Drill Bit Do You Need for Plexiglass? The gradually go up in drill bit sizes until you reach your desired diameter. Any injury, damage, or loss that may result from improper use of these tools, equipment, or from the information contained in this video is the sole responsibility of the user and not Know How Now. Plexiglass (acrylic) can be used for a number of applications such as signage, displays, aquarium tanks, custom computer cases, and more. I use a band saw to cut my lexan. Also, wearing gloves will protect your hands from the blade and from getting burned; Lexan can get very hot. Clamp it down using C-clamps, and remember to use proper blades with a large number of teeth. 8) Cut slowly and evenly to avoid cracking or breaking the Plexiglass. Large-diameter hole saws may be made by inserting a piece of band saw blade in a groove machined in a steel disc and holding it with set screws. If its not treated with UV protection, itll turn yellow from exposure. You can use a plastic/metal jigsaw blade to cut lexan, typically the more teeth the better. Yes. I'm pretty sure that would work well. Proceed to cut the line without forcing the saw. JavaScript is disabled. All rights reserved 2018-2021 | NinjaDIY.com, Place the sheet of Lexan on a straight and sturdy surface. Using the right kind of tools is important when working with many types of plastics. There are several ways to cut Lexan. That said, Lexan is a polycarbonate resin thermoplastic material that can be used for many DIY projects around the house. Before cutting, mark the lines with a pencil. #9. Hole saws are stocked in sizes from 516-inch to 4-inch diameters. However, the most accurate and precise way to make cuts on Plexiglass is by using a jigsaw. Additionally, it reduces vibration. Sound advice. This reduces the risk of bleeding or running. To start your project, you should make sure you have a fine tooth saw blade on your circular saw. The water will make the cutting process a lot easier. Scoring preferably works on sheets less than " (6.35mm) in thickness. First I emptied the can Ask Question Comment Step 2: Then I cut off the inner rim Ask Question Comment Step 3: Then I drilled a hole in the center Ask Question Step 4: I used a rotary tool to cut teeth Ask Question Download Step 5: I sharpened one end of the bolt [/wpsm_pros][/wpsm_column][wpsm_column size=one-half position=last][wpsm_cons title=CONS:]if(typeof ez_ad_units!='undefined'){ez_ad_units.push([[250,250],'ninjadiy_com-banner-1','ezslot_7',114,'0','0'])};__ez_fad_position('div-gpt-ad-ninjadiy_com-banner-1-0');if(typeof ez_ad_units!='undefined'){ez_ad_units.push([[250,250],'ninjadiy_com-banner-1','ezslot_8',114,'0','1'])};__ez_fad_position('div-gpt-ad-ninjadiy_com-banner-1-0_1');.banner-1-multi-114{border:none!important;display:block!important;float:none!important;line-height:0;margin-bottom:15px!important;margin-left:auto!important;margin-right:auto!important;margin-top:15px!important;max-width:100%!important;min-height:250px;min-width:250px;padding:0;text-align:center!important}. The blade were going to use its a 2 flute carbide router bit. This is particularly important when cutting through sheets of Lexan. Ideal situation would be to drill the lexan on a drill press. The secret is to go EXTREMELY SLOW when cutting the Lexan with the table saw. But the ones above are the most famous ones if you want. Any potential leeching from using this as a dosing container? Thats why its important to use the right tools and take special care while handling Lexan. Let the hole saw do the cutting Low RPM and low pressure is the best course of action. 2) Place the Plexiglas on a cutting board or other stable surface. Use a saber saw or jigsaw with a fine-toothed blade for larger circles. Here are some of the benefits of using a jigsaw when cutting Plexiglass: Overall, the jigsaw is the best tool for making cuts on Plexiglass. dtengineering March 20, 2014, 8:48pm #16. If you do not follow these steps, your Lexan sheet will chip and warp. A few ways to cut different thickness sheets.Another Know How Now video you might like: Cut Lexan Polycarbonate Shee. Normal glass can corrode when used with chemicals, whereas Lexan is resistant to acids and chemicals. If it pops through too hard it will send a crack or two off the circle that doesn't look too good. Slowly and carefully start drilling into the plexiglass, following the pilot hole you created. You can use a hole saw to cut a circular hole in plexiglass, but there are a few things you need to keep in mind when doing so. Check out the channel with this link:https://www.youtube.com/@Know-How-Now/videosDisclaimer: Due to factors beyond the control of Know How Now, I cannot guarantee against improper use or unauthorized modifications of this information. Score the Cut Line. Lexan is a brand name. Mount your Plexiglass Sheet. The black 2025 is glossy on both sides. On the other hand, Lexan also has some cons that should be kept in mind when using this material. Here's a . Turn on the jigsaw and let the blade pick up speed, before gently easing it into the path of the cut. Another way with or without a hole already, is to trace the bulkhead (Again, very important! This will determine the size of hole saw you need to use. It does say that you can mill Lexan with at bit more like the Dremel Router bits they recommend 25,000 - 30,000 RPM. 4. If you score it properly, it wont shatter. Close Shouldnt be too hard. Just be careful not to overheat it or else the Plexiglass could crack. The dust relief holes make both types of bits cut remarkably efficiently. Finally, if you are cutting the Lexan sheet in a curved line, you can use a band saw or a jigsaw. Use a glass cutter to cut through the marked points. By creating an account you agree to the Hunker. As an Amazon Associate we earn from qualifying purchases made on our website. Another issue is when you need to make a round hole. Mark the center of the hole you wish to cut with a permanent marker. Cut Plexiglass with a Jigsaw. By thebetatesters. With a little patience, you should be able to cut through the plexiglass easily. In order to avoid that, you should use a spray bottle with water that youve place in the freezer for some time. That will be your guide to follow with the router. Hunker may earn compensation through affiliate links in this story. Ensure that the off-cut falls freely. Is this true for Lexan (polycarbonate)? When cutting into Lexan with a jigsaw, you first should clamp the Lexan tightly to a work table. Save my name, email, and website in this browser for the next time I comment. On top of that, the material is cheap and less fragile than others. Warmer paints evaporate faster once they land on the surface. If youre wondering if you can cut Lexan with a Dremel, the answer is yes. You should avoid using MEK, a chemical solvent, on the face of Lexan. is another name for clear polycarbonate sheeting that is used in many applications. Make sure that you dont lay anything (like tools) on top of your Lexan sheet. 4 In. Practice on Tinier Acrylic Piece. Use a Forstner bit to cut circles up to three inches in diameter. Plexiglass is also known by the brand name Lucite or Acrylite. We dedicate a lot of time and energy to create great content on this website in order to bring you the best information and tips related to DIY & tools! You'll see the indicated holes right in the template. This simple repair will make your Plexiglass look as good as new and it will be much stronger than if you had tried to glue it together without scoring the line first. Its mainly used for windows, doors, storefronts, shower curtains and more. Start your circular saw and let it reach full speed. Wear eye protection and gloves to protect your hands and face from any stray Lexan particles. Start by drilling a hole in the plexiglass. 6 TPI Clean for Polypropylene T-Shank Jig Saw Blades But first, for those of you who never used this material before. The problem with using a router to cut Lexan is that if youre not having the right speed when you go with your bit through the piece of Lexan if you go to slow through the Lexan, it can actually close itself back behind your cut. This also works for a forstner (although you can cut anywhere inside the waste. We aim to inspire with top notch advice from professionals and easy to follow DIY guides. 9) If you need to make a curved cut, you can use a heat gun to heat up the plastic and then bend it to the desired shape. Slowly and carefully start drilling into the plexiglass, following the pilot hole you created. Carefully measure the cut lines and mark them with a marker or pencil. Set the drill stop with a few sheets of paper below the forstner so that only the tip penetrates the bottom. Just have good backing, go slow, and reverse the piece before you go all the way through it and drill from the other side to prevent chips/cracks. Keep in mind that cutting Lexan with a circular saw is only the recommended route if you have Lexan sheets that are 3mm or thicker. Next, attach the cutting wheel to the rotary tool and put on your safety glasses. Lexan is another name for clear polycarbonate sheeting that is used in many applications. Question #5. Otherwise, you may end up breaking the sheet or damaging it. If you do not, you might end up with an ugly seam. Any good quality bimetal is my go to for holes in plastic. Put the plexiglass sheet on the top of your sawhorse or you workbench and make sure that it is completely clean. Diamond grit hole saws dont cut as much as they grind . completely inappropriate for acrylic where you actually are cutting. The cutting depth of the Hole Saw Kit is between 0 and 25 mm on plastic materials. You should not use abrasive materials such as sandpaper or polishing compound. If you would like to change your settings or withdraw consent at any time, the link to do so is in our privacy policy accessible from our home page.. When using a jigsaw to cut Plexiglass, the ideal blade to use is: (BOSH T121AF Speed / Metal Blade) typically used to cut metals. Youll also find the edges of the Lexan seem deformed and melted. Having said that here are a few other ways to cut a sheet of Lexan using different tools.if(typeof ez_ad_units!='undefined'){ez_ad_units.push([[250,250],'ninjadiy_com-medrectangle-4','ezslot_10',124,'0','0'])};__ez_fad_position('div-gpt-ad-ninjadiy_com-medrectangle-4-0'); If youre wondering how to cut a sheet of Lexan by hand, using a utility knife with a brand new blade can do the job. Choosing blades with teeth that are too far apart can splinter the Lexan at the edges. This is important to minimize the vibration which could lead to chipped plastic or even throw your saw off of its path. Maryland, USA. You should also keep your hands away from the blade while cutting. Either of one these should be fitted with a blade designed to cut metal, and its teeth should be spaced anywhere from 2 mm to 4 mm apart. Be sure to move smoothly and let the blade work at its own pace. If youre wondering how to cut Lexan, this article can help. Atable saw is an excellent tool for cutting polycarbonates that are more than 0.5 thick. To create a line in the Lexan sheet, use a pencil. Thats why moving the saw blade too slowly can overheat the Lexan and make it warped. Clamp the sheet if needed. The heat from the spinning saw blade not only causes the Lexan to overheat, but it can also melt and warp it if you keep lingering over the cut for too long. Use as many clamps as is necessary to secure the sheet. The drilling is done in two steps. In my opinion, the best way to cut Lexan is by using a table saw using a fine saw teeth blade (excluding laser cutter since its expensive). When cutting Lexan, use a steady motion, and wait a few seconds before making any further cuts. If your interior lights are staying on after you turn the car off, it could be a sign of a Home improvement can increase the value of your home significantly and it can make each moment you spend in your house better. Attach your hole saw to your drill, making sure that the teeth are facing outwards. Although Lexan may look similar to Plexiglass or acrylic, its actually quite different from these two. Follow these steps to get started: If you follow the steps above closely you should be fine. Always begin painting with the darker colors and work toward the brighter hues. 979. Although you can use a Dremel (on Amazon) to cut Lexan, its not the best tool for this job as it uses friction to cut. Draw a straight line on the Lexan sheet. 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Tool for this job any good quality bimetal is my go to for holes plastic... Or Acrylite an ugly seam 8 ) cut slowly and carefully start drilling into the.... That can hold the sheet or damaging it you created gloves will protect your away! The gradually go up in drill bit sizes until you reach your desired.! Polypropylene T-Shank jig saw blades but first, for those of you who never used material! Tools is important when working with many types of plastics the Plexiglas on a cutting or! The secret is to use a table saw any place, that can cut it for....