Replies

1. 
   Ricky_Yu | Feb 08, 2004 12:55pm | #1

   Plexiglas can be cut with a carbide-tipped sawblade, but beware of the noxious odor. I use a 10" 50-tooth blade with an ATB&R tooth pattern only because it is my beater blade. Occasionally, I'll get some saw marks and some minute chipping. I remedy this by cutting the panels slightly oversized (about 1/32" or even 1/64") and filing the edges smooth. As to minimize surfacial scratching, the best advice is to leave the protective wrapping on the plexiglas while you're cutting it and leaving it on until the last possible moment, which is usually until you're ready to install them.

2. 
   WayneL5 | Feb 08, 2004 05:29pm | #2

   Cutting slightly ovesize and cleaning up the edges with a router works well.

3. 
   YvesG | Feb 08, 2004 05:42pm | #3

   Cutting slightly ovesize and cleaning up the edges with different sandpaper grit work well for me. Actualy, by using hard rubber sanding block, I achieved a slightly convex edge that were miror finised.

4. 
   USANigel | Feb 08, 2004 06:49pm | #4

   Why not use glass? Have it cut and polished to size and will last without scratching.

1. 
   PlaneWood | Feb 09, 2004 01:56am | #6

   The glass doors on the component cabinet I built for my son lasted 6 months till one got broke.  Was expensive smoked glass, too.

   PlaneWood by Mike_in_Katy (maker of fine sawdust!)PlaneWood

5. 
   forestgirl | Feb 08, 2004 11:49pm | #5

   Herm, you didn't specify how big the Plexi needs to be, but I've successfully cut plexi to about about 24"x32" using a hand-held plastic-specific knife bought at a hardware store.  I clamped a straight-edge to the bench the plexi was sitting on and carefully scored the surface, then went over it 3 or 4 times (after practicing on a scrap piece).  Then snapped it off.  Any needed clean-up can be done with sandpaper.

   If you'd like a picture of the knife, let me know, I'll post it.  There are plastic-specific sawblades out there, but they're not cheap. 

   forestgirl Another proud member of the  "I Rocked With ToolDoc Club" .... :>)  you can take the girl out of the forest, but you can't take the forest out of the girl ;-)

6. 
   forestgirl | Feb 09, 2004 10:38am | #7

   PS:  As far as scratching the surface goes, the plexi comes with protective plastic film on it.  That will protect it if you're careful.

   forestgirl Another proud member of the  "I Rocked With ToolDoc Club" .... :>)  you can take the girl out of the forest, but you can't take the forest out of the girl ;-)