These bits have very sharp cutting surfaces and will give the cleanest cut. (Again, very important! 2) Place the Plexiglas on a cutting board or other stable surface. However, its worth noting that Lexan can be cut using a table saw. 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. Score the Cut Line. as you lose the solid material for the pilot hole in the hole saw. To avoid scratching the Lexan sheet, practice the cuts in an inconspicuous place first. Additionally, it reduces vibration. Using a marker to draw the path that you want to cut on both sides of the protective film. However, today its used generically for multiple companies products. As with any other tool, circular saws can be dangerous. The normal 118* or 135* metal drills can break sheet plastics unless used very slowly far from an edge. 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. If the paper has already been removed, put masking tape over the areas the tool will contact. This helps to reduce the vibrations of the blade and ensures a more precise cut. Just let it get ice cold. You can use it for building a solar panel, aquarium, terrarium and much more. This site uses Akismet to reduce spam. Lexan is a common material used in many home or construction projects. I've worked with both at design:builds. Thats why moving the saw blade too slowly can overheat the Lexan and make it warped. Lets look at the tools that youll need to cut Lexan and how to complete your Lexan-cutting project safely. Cutting a Circle. Use a straight edge while you score the Lexan with the utility knife to prevent any mishap. The drilling is done in two steps. Thats why we created this step-by-step guide on how to cut Lexan. On top of that, the material is cheap and less fragile than others. 3.2.3 Tighten the Hole Saw Attachment. Yes. They should also have alternating 45-degree bevels in order to effectively reduce unnecessary chipping. Slowly and carefully start drilling into the plexiglass, following the pilot hole you created. Circular Saw Instructions Using your blade that is carbide-tipped, ensure that your tooth spacing is a half-inch or less when using a circular saw to cut Lexan. Here's a . Use this information at your own risk. Hunker may earn compensation through affiliate links in this story. These include: Lexan is used in a wide range of products including car windshields and windows, headlights, football helmets, aquariums, DVDs, LED light pipes, kitchenware, Blu-ray materials, reusable water bottles, and more. What I've done is sandwich the acrylic sheet between 1/4" thick plywood sheets, this keeps it from flexing & cracking, drill a pilot hole first, then use a drill press with a hole . Simply cutting through plexiglass is one thing. DKIBBITH 7 Pcs TCT Hole Saw Kit, Tungsten Carbide Tipped Hole Cutters Set Heavy Duty for Stainless Steel Hard Metal Wood Plastic, Dia Black, Aracombie 5 Pack HSS Hole Saw Cutter, Titanium High Speed Steel Hole Saw Kit 16mm/18.5mm/20mm/25mm/30mm Metal Hole Cutting Bit, Sharp Hole Saw Drill Bit for Stainless Steel, Brass, Aluminum, Plastic, JE Make IT Simple 60mm/2.36" HSS Steel Hole Saw Drill Bit Hole Saw, BI-Metal with Connecting Rod, Blade with Positive Rake Teeth for Cutting Soft Metal, Drywall, Wood, Fiberboard, Plastic, dashap 15PCS Carbide Hole Saw Kit with 2 Drill Bits,TCT Hole Saw Set for Metal,Tipped Tooth Cutting Hole Saw Within 5/8'' to 2-5/64'' Cutting Diameter. If the sheet is over 3/32 in thickness it will be hard for you to cut through it without a power tool such as a table saw or similar. Im sure you dont have one lying around the house. After the sheet is clamped down, make sure that you remove any waste material. In addition to a saw or a utility knife, youll need the following supplies: Before cutting Lexan, its vital to keep the following considerations in mind: Now that youre ready, lets look at how you should use the circular saw to cut Lexan. Can I use the same saw on the acrylic? if(typeof ez_ad_units!='undefined'){ez_ad_units.push([[336,280],'ninjadiy_com-leader-1','ezslot_11',137,'0','0'])};__ez_fad_position('div-gpt-ad-ninjadiy_com-leader-1-0');There are many other ways people have tried cutting Lexan. Put the sheet on a working surface. Removing paint from your car's interior can be a tricky and time-consuming process. You can use a clamp-on vises to make sure the sheet is fixed and stable. The best way to avoid chipping or cracking the lexan is to use a softer material, such as rubber or foam, to protect it. Insert the correct bit size into your Dremel. While this could be an article all by itself, here are a few quick tips to help you out. Plexiglass is also less costly, which is what makes it a very popular material to use. Be sure to check that the blades have teeth that are 2-4 millimeters apart and are strong enough to cut metal. Continue to make your cut until you reach the end of the sheet. Just be careful not to overheat it or else the Plexiglass could crack. Use with Spyder's Rapid Core Eject arbor system to . Its free. When using a table saw, make sure that the blade has fine teeth, as the material may break or dent if you use a coarser one. Be sure to keep pets and children away from your work area. Adjustable Hole Saw Drywall Circle Cutter Drill BitAdjustable Hole Saw for Wood,Plastic,PVC and Drywal (1-3/16" to 7-7/8" (30mm - 200mm)) 2 $1399 - $1759 Save 8% with coupon FREE delivery Mollom Heavy Duty Carbide Hole Saw, Hole Cutter cuts Stainless Steel, mild Steel, Iron, Copper, Brass, Plastic (1-1/4'' 32mm) 427 $939 - $6999 FREE delivery Then, run along the critical edge of the tape with your thumbnail. Cutting the sheet before the saw has reached full speed could cause the teeth of the blade to snag on the sheet and create a jagged or choppy cut. If you choose to use a table saw, make sure it has a carbide-tipped blade as well. Is this true for Lexan (polycarbonate)? Additional comment actions. Contact us today to start your advertisement! 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. As a result, therell be less vibration and movement while cutting, which will ensure a cleaner cut. An example of data being processed may be a unique identifier stored in a cookie. However, Plexi is a horse of a different color. If you need to cut Lexan on a curve, use a jigsaw or band saw. By creating an account you agree to the Hunker. Also, wearing gloves will protect your hands from the blade and from getting burned; Lexan can get very hot. Logged. Work slowly and surely, taking your time. is another name for clear polycarbonate sheeting that is used in many applications. While it is a common material, many people struggle to learn how to cut Lexan. Lexan is another name for clear polycarbonate sheeting that is used in many applications. If its not treated with UV protection, itll turn yellow from exposure. Know How Now recommends safe practices when working and or with tools seen or implied in this video. This will mark where you need to drill. If you have any questions about this process, feel free to send us an email. Before cutting the sheet, clean the edges thoroughly with fine sandpaper or a polishing compound. It is definitely the stronger of the two (although it will scratch more easily.) a diamond coated hole saw and some clay around the area you want to drill. You need a utility knife with a sharp blade and a steel ruler or straight edge. First, start by clamping the acrylic sheet down with table clamps to prevent slipping. However, it is recommended to use a guide to ensure a straight cut. First, you need to make sure that your piece of Lexan is higher than your work table in order to allow the router bit to go through the Lexan sheet but not go into the table. Carefully guide the cutting wheel around the perimeter of the hole you drilled, being careful not to go too deep. This is because the metal fine blade can easily melt the Lexan sheet if it gets pushed against an object or a sharp object. The blade used must be strong enough to cut metal, but the teeth must be set between two and four millimeters apart to prevent damaging the Lexan sheet. Pancake Compressor Cart DIY or buy? It will reduce scratching and splintering. 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). Any power tool can be used to cut Lexan according to your measurements. 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. Posted: 3/3/2023 3:10:29 PM EDT [#45] Cut it all the time with table saw. Clamp both sheets to a secure surface. Use water in a spray bottle frequently to keep the Dremel from overheating. Cutting Lexan with most any saw is possible. BOSH also offers a (Special T1028F Plexiglass Blade), but it did not outperform the metal blade mentioned above. cheesefight . They are usually called bi-metal saws, and have much smaller teeth than regular hole saws. Some people prefer to use a rotary tool with a saw blade attachment, while others might choose to use a hand saw. Shop products from small business brands sold in Amazons store. Acrylic sheets can be machined with most shop tools. Step 1 Leave the backing paper attached to the sheet while you are cutting. Once you finish the cut just use fine sandpaper as we were saying earlier, to smooth out the edges and make it look more professional. Heat up your paint first. Working naturally lowers your risk of having large chunks gouged from the Lexan material. We may earn commissions if you buy through our links. However, its essential to use the right blade. Then, you can extract the chips with minimal heat. Section 3 How to Use a Hole Saw. Use ruler to be as precise as possible. Benefits of using a jigsaw when making cuts on Plexiglass. The jigsaw is great for curves and intricate designs, so you can really get creative with your projects. 979. Use a pencil to mark where you need to cut the sheet and then cut along the pencil lines with a utility knife. 1996-2023, Amazon.com, Inc. or its affiliates. Start your circular saw and let it reach full speed. You should also wear protective clothing while cutting Lexan. Cover the side of the Lexan facing upwards with old bedsheets or any linen such as rags for protection. Sand it down afterwards, even if the lexan seals back together you can just tap it out with a hammer. Coarse-tooth saws should be used for cutting Plexiglas acrylic sheet. Lexan can become discolored over time due to UV rays. I drilled a tank with a diamond hole saw and it was glass. It will take around 10 cuts. cack01 Member Joined Mar 7, 2002 Location San diego or UC Davis Jun 8, 2004 #9 We and our partners use cookies to Store and/or access information on a device. Double-check your measurements before making a hole. The ideal tooth density is between three to five teeth per inch. 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. Works with a maximum speed of 1000 RPM; . Place the off-cut over the edge. Line up the drill bit and make a hole while moving at a steady pace. So to cut polycarbonate using a table saw, begin by measuring and marking your cut. Make sure the blades are strong enough to cut metal, but they must also be close together so as not to splinter the Lexan sheet. 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. [wpsm_column size=one-half][wpsm_pros title=PROS:], [/wpsm_pros][/wpsm_column][wpsm_column size=one-half position=last][wpsm_cons title=CONS:]. Continue drilling until the hole saw has cut through the entire thickness of the plexiglass. Be sure to score both sides of the sheet. Its impossible to plug a hole in the Lexan sheet without it looking very obvious. You are using an out of date browser. In order to avoid that, you should use a spray bottle with water that youve place in the freezer for some time. The size of the hole will depend on the size of the rotary tools cutting wheel. Many DIY plexiglass and lexan sheet projects require a hole or two. Move the scored section to the edge of the work surface. 3.2 Attach the Hole Saw to Drill. The special tip design carves through the plastic (not for use with wood or metal). 1. I've drilled holes up to 1/4" diameter in lexan using ordinary twist drill bits and light pressure. We used table saws with acrylic blades to cut all of it into sized sheets. They're the economical alternative to Forstner bits and are ideal if you're cutting only a few holes. Be aware that this area will be matte now, but that shouldnt matter much if you are painting it. Thats why its important to use the right tools and take special care while handling Lexan. Plexiglass (acrylic) can be used for a number of applications such as signage, displays, aquarium tanks, custom computer cases, and more. 3. A firm grip . You can use a small paintbrush to do touchup work on Lexan. The tool will give you a much precise and clean cut for your project. It can be molded into almost any shape from its liquid state but it is most often encountered for project use in 1/16-inch to 3/4-inch thick sheets. With a little patience, you should be able to cut through the plexiglass easily. As this material is transparent, you dont want it to get scratched from either side. Before cutting, make sure that the sheet is supported. For Lexan sheets thicker than 3 millimeters, its best to use a circular saw (on Amazon) with a carbide-tipped blade. By following these tips, you will be able to safely use a circular saw. Eshopps Eclipse and Drilling Questions. Make sure you use a straightedge to effectively guide your knife. 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. 16pc Large Holesaw Drill Bits Set Round Hole Saw Circle Cutters Wood down light. Carefully measure the cut lines and mark them with a marker or pencil. Mark the points where you need to cut through. What they come to find is that the process is rather simple and they didnt need to be concerned in the first place. Just cut the circle. Pull off . Our black plexiglass sheets are cast and come with a paper masking. 6) Follow the manufacturers instructions for your power tool. Due to factors beyond the control of Know How Now, no information contained in this video shall create any expressed or implied warranty or guarantee of any particular result. Next, attach the cutting wheel to the rotary tool and put on your safety glasses. 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. Additional comment actions. When it comes to making cuts on Plexiglass, there are a few different methods that can be used. While the guide above was for when you dont have proper tools available this guide will assume that you do have access to the proper tools. Do you need one? If you need to cut Lexan, you can use any power tool to cut a piece of this plexiglass material to the size that you need. Continue with Recommended Cookies. Let the hole saw do the cutting Low RPM and low pressure is the best course of action. Position your plexiglass on a sturdy table. But its very expensive for most of us DIYers. Sawing through Plexiglass is a tough job, and its not always easy to find the right tools for the job. Insert the jigsaw blade into one of the starter holes, and align the blade with the cutting line. Use a scoring knife to cut a narrow groove in the acrylic sheeting. Measure the thickness of your plexiglass. Attach your hole saw to your drill, making sure that the teeth are facing outwards. Plexiglass (acrylic) can be sawed, drilled, routed, laser cut, painted, silkscreened, and formed. Using a jigsaw is not easy, so be sure to watch your fingers carefully! Here we will show you how to fix a broken piece of Plexiglass without replacing it using a few simple tools and techniques. Shouldnt be too hard. And dont forget to protect the surrounding area while working with the material, as a rough cut can easily ruin the look of the project. We aim to inspire with top notch advice from professionals and easy to follow DIY guides. Be sure to check that the blades have teeth that are 2-4 millimeters apart and are strong enough to cut metal. 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! Plexiglass, Lexan, Plastic Drill Bits. You should also set your saw to 4,000 revolutions per minute for a smooth cut. The black 2025 is glossy on both sides. Maryland, USA. Plexi is best just scored and snapped. 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. For a better experience, please enable JavaScript in your browser before proceeding. Youll find it around the. Price and other details may vary based on product size and color. Dont force the blade through. Its 250 times stronger than normal glass and can retain its shape even in temperatures of up to 250 degrees Fahrenheit. If you push it through too slowly, the blade could overheat and melt your plastic material. 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. Uv protection, itll turn yellow from exposure be concerned in the freezer for some time practice cuts! These tips, you should also have alternating 45-degree bevels in order to avoid the! The paper has already been removed, put masking tape over the areas the tool will contact too! With both at design: builds is not easy, so be sure to check that the are! While this could be an article all by itself, here are a few quick tips to help out. Very popular material to use a straight cut and techniques, silkscreened, and align the blade could and. 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