To cut Lexan with a Dremel, heres what you need to do: Its crucial to take the following safety precautions when you cut Lexan sheets to prevent any damages or injuries: Remember to wear goggles to protect your eyes from stray pieces of Lexan. As the plexiglass becomes smoother, transition to successively finer grits.. As you drill, the plexiglass will start to melt. 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.. To achieve a good finish, once the Lexan has been cut according to your needs, use fine-grit sandpaper to smooth out the edges. 3.2.4 Insert the arbor into the Chuck and Tighten. The tool will give you a much precise and clean cut for your project. Score your cut line on the material with a knife. If you push it through too slowly, the blade could overheat and melt your plastic material. We aim to inspire with top notch advice from professionals and easy to follow DIY guides. Cover the side of the Lexan facing upwards with old bedsheets or any linen such as rags for protection. 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. Heat up your paint first. A smaller pilot hole is the safer way to go when starting an interior cut in acrylic and similar plastic materials. ToolsCritic.com 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. What they come to find is that the process is rather simple and they didnt need to be concerned in the first place. Feb 9, 2005. Then, run along the critical edge of the tape with your thumbnail. This hole should be just slightly smaller than the size of the pilot bit of your hole saw. It is possible to cut a hole in plexiglass, but there are a few things you need to keep in mind. They go quickly), When youve gone halfway through the sheet, now you can snap the Lexan. By thebetatesters. Additionally, it reduces vibration. Just be careful not to overheat it or else the Plexiglass could crack. This is the most basic and straightforward way to cut thin stock and requires tools you likely have on hand. If its not treated with UV protection, itll turn yellow from exposure. 2. Mark or scribe the circle and drill a 1/4-inch pilot hole slightly inside the perimeter. It may not display this or other websites correctly. Find a place, any place, that can cut it for you. It will take around 10 cuts. 4. Still, the blade did a great job when cutting Plexiglass. It is not necessary to use a guide when cutting lexan with a jigsaw. Make sure you use a straightedge to effectively guide your knife. A sharp utility knife can scratch the Lexan sheet. As this material is transparent, you dont want it to get scratched from either side. i though they were crazy, but a quick check on youtube got me here----. Mark the center of the hole you wish to cut with a permanent marker. Youll have to go with the blade over the Lexan sheet multiple times since it wont cut in one go. Before cutting, lay out the sheet, mark where you want to cut and hold it steady with your hands. Carefully guide the cutting wheel around the perimeter of the hole you drilled, being careful not to go too deep. GoImproveHome is reader-supported. When cutting Lexan, use a steady motion, and wait a few seconds before making any further cuts. dtengineering March 20, 2014, 8:48pm #16. 979. Move the scored section to the edge of the work surface. 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. When using a jigsaw to cut Plexiglass, the ideal blade to use is: (BOSH T121AF Speed / Metal Blade) typically used to cut metals. The ideal tooth density is between three to five teeth per inch. Either clamp it or have someone hold it in place. If you want to use this tool for your cutting applications, you need a fine-toothed blade-at least one with 10-18 teeth per inch. Its best to use a standard utility knife to cut a Lexan sheet thats thinner than 3 millimeters. 6) Follow the manufacturers instructions for your power tool. If youre still having trouble or if the Plexiglass is too thick then you can always ask for help from a professional. Question #5. Before cutting, make sure that the sheet is supported. Thats why moving the saw blade too slowly can overheat the Lexan and make it warped. You can also use a spiral flute router bit for Lexan. We use cookies to personalise content and ads, to provide social media features and to analyse our traffic. Either clamp it or have someone hold it in place. Privacy PolicyMail: contact@goimprovehome.com, How to vent a microwave on an interior wall, How Long Does It Take To Replace A Radiator - Full Guide Included, How To Cut Hole In Brick Wall - The Ultimate Guide, link to How to remove paint from car interior, link to Why are my interior lights staying on. Then, you can extract the chips with minimal heat. Bend the overhang side of the sheet with quick and even motion. Hunker may earn compensation through affiliate links in this story. First, drill a locator hole through the countertop at each of the three marks. Continue to make your cut until you reach the end of the sheet. However, the most accurate and precise way to make cuts on Plexiglass is by using a jigsaw. Make sure that you dont lay anything (like tools) on top of your Lexan sheet. MVC said: A bi-metal hole saw will cut acrylic just fine. 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. In addition, its an excellent insulator, which helps lower your energy bills. Then, use a utility knife to cut along the line. If the edges are too sharp, you can use a small flame to soften them. You can also use a table saw or a circular saw and achieve good results. And if you really have to cut Lexan with a Dremel, my suggestion is to cut off a bit more of your measurements and use some fine-grit sandpaper to reduce it to your exact measurements.if(typeof ez_ad_units!='undefined'){ez_ad_units.push([[580,400],'ninjadiy_com-large-leaderboard-2','ezslot_9',136,'0','0'])};__ez_fad_position('div-gpt-ad-ninjadiy_com-large-leaderboard-2-0'); Its as simple as that. It will be helpful for you to make an informed decision. Do you need one? All you need is a sharp utility knife and a straight edge. Close When cutting sheets of Lexan, you should use a circular saw with a blade with alternating 45-degree bevels. Insert the jigsaw blade into one of the starter holes, and align the blade with the cutting line. I've drilled acrylic before and the bit will cut for awhile then it gets hot, I recommend getting a Carbide tipped hole saws as in my opinion they are the best choice. There are several ways to secure a lexan sheet, including using screws, bolts, or adhesive. But its very expensive for most of us DIYers. You can cut Lexan with a router. Leave the backing paper attached to the sheet while you are cutting. Cutting Polycarbonate Using a Table Saw. Whatever your purpose for using this versatile material, you now know how to cut Lexan effectively. Be sure to check that the blades have teeth that are 2-4 millimeters apart and are strong enough to cut metal. Know How Now recommends safe practices when working and or with tools seen or implied in this video. It does say that you can mill Lexan with at bit more like the Dremel Router bits they recommend 25,000 - 30,000 RPM. Diamond grit hole saws dont cut as much as they grind . completely inappropriate for acrylic where you actually are cutting. Similar precautions should be applied when drilling a hole in Lexan: Save my name, email, and website in this browser for the next time I comment. The blade were going to use its a 2 flute carbide router bit. Using other tools might work but the risk of breaking the Lexan its high.Plus the cut will not be very accurate. Put the sheet on a working surface. Be sure to move smoothly and let the blade work at its own pace. Acrylic Industrial Plastic Round Tubes, PTFE . Therefore, be careful while handling Lexan and use protective gear. Mark the Plexiglas with a grease pencil where you want to cut it. 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. Youll achieve very good results if you use a tool such as a circular saw or table saw as well. The blade will also make the cut smoother. Haha, Yeah costed almost $20 for it. Sound advice. Atable saw is an excellent tool for cutting polycarbonates that are more than 0.5 thick. 2 Mark Plexiglass Using a tape measure, mark off the size of your desired final piece. First, start by clamping the acrylic sheet down with table clamps to prevent slipping. Start your circular saw and let it reach full speed. 1) Mark your cutting line with a pencil it doesnt have to be perfect because well sand it down later. Amazon, the Amazon logo, AmazonSupply, and the AmazonSupply logo are trademarks of Amazon.com, Inc. or its affiliates. Be sure to score both sides of the sheet. So thank YOU for your support! 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. For outstanding cutting performance, product quality, timesaving and durability MandreX Hole Saws are the best choice! 3.2.2 Attach the Hole Saw. Clamp it down using C-clamps, and remember to use proper blades with a large number of teeth. Put the blade through the hole to start the cut, then saw around the circumference. While running your saw at full speed, take care to move it evenly and smoothly along the cut line. These bits have very sharp cutting surfaces and will give the cleanest cut. If you dont have access to power tools like a saw or drill press then use the edge of something else rigid such as a metal ruler or even another piece of Plexiglas thats the same thickness. Vearter TCT Carbide Hole Saw Kit for Hard Metals, 5/8''-2'', 10 Carbide Bits with Pilot Drill,for Stainless Steel, Iron, Aluminium, Alloys, Plastics, Etc. Once youve cut all the way around the hole, you can remove the center piece by gently tapping it out with a hammer or another object. Work slowly and surely, taking your time. These are the bits you need for drilling Plexiglass, Lexan polycarbonate, PETG, and other clear plastics. It will reduce scratching and splintering. Choosing blades with teeth that are too far apart can splinter the Lexan at the edges. The pilot hole should be at least 1/2 the diameter of the final hole. Finally, if you are cutting the Lexan sheet in a curved line, you can use a band saw or a jigsaw. Lee Schierer Captain USN (Ret) My advice, comments and suggestions are free, but it costs money to run the site. Draw a straight line on the Lexan sheet. However, its essential to use the right blade. Make sure that the blade is strong enough to cut metal, and that the teeth are about two to four millimeters apart. This will give you a smooth cut.. nothxplz . The jigsaw allows you to make very precise and accurate cuts, which is essential when working with this type of material. Dont force the blade through. You should also keep your hands away from the blade while cutting. It is definitely the stronger of the two (although it will scratch more easily.) Section 3 How to Use a Hole Saw. NO pressure (dont push, let the tool do all the work.) Additional comment actions. Clamp both sheets to a secure surface. I paid $50 for the diamond ones at Home Depot. Mark the points where you need to cut through. Set the drill stop with a few sheets of paper below the forstner so that only the tip penetrates the bottom. Secure the plexiglass sheet to your work surface. cack01 Member Joined Mar 7, 2002 Location San diego or UC Davis Jun 8, 2004 #9 You can also use shears for these sheets if theyll help you make the cuts you need. You can use a table saw, circular hand saw, jig saw, or band saw to cut Lexan. Additional comment actions. Yes. 7) Make sure to wear safety goggles while cutting. If you. Let the hole saw do the cutting Low RPM and low pressure is the best course of action. Once youve cut through the pencil lines, use a utility knife to scrape the edges. You'll see the indicated holes right in the template. Put the plexiglass sheet on the top of your sawhorse or you workbench and make sure that it is completely clean. Hole saws Mandrex Hole saws The very best Hole Saws for all materials. These blades are typically 80 to 85 tooth 10-inch blades. Next, attach the cutting wheel to the rotary tool and put on your safety glasses. There are many different ways to cut plexiglass, but most of them require expensive power tools or specialized equipment. 5) If youre using a power tool, make sure to use the proper blade or bit. Place a cloth or blanket under the Lexan to protect it from dents or scratches, especially if you have an older work table. Another issue is when you need to make a round hole. 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. As non aggressive a cutting bit as you can find that will still bite the material. Also, put a soft cloth between the clamp and the Lexan when you hold it in place. Key Features. Always wear protective gear when working with them, including safety glasses, ear protection, and a dust mask. Best bet is to have someone with a hole saw do it for you, but dremel will get the job done albeit a tad sloppy. Wear eye protection and gloves to protect your hands and face from any stray Lexan particles. Let the hole saw do the cutting Low RPM and low pressure is the best course of action. While it is a common material, many people struggle to learn how to cut Lexan. Place the sheet over a hard edge with groove-side up. Video of the Day Step 2 Secure the plexiglass sheet to your work surface. Step 1 Leave the backing paper attached to the sheet while you are cutting. The normal 118* or 135* metal drills can break sheet plastics unless used very slowly far from an edge. 4) Smooth out any rough edges with sandpaper before moving on to the next step. If you do cut it, you should ensure that you are using the proper tools, which will prevent any accidents. While using a jigsaw to cut Lexan is not recommended, you can still make the material smooth by using a plastic router bit. 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. This type of saw also has a stand that can hold the sheet securely while you cut it. Its also very easy to install. The gradually go up in drill bit sizes until you reach your desired diameter. #8. Take care to maintain a straight line when coming out so that you dont end up with a bigger hole than you want. And do I need to keep spraying water on the hole when drilling it? This will mark where you need to drill. Well also talk about how to clean the edges of Lexan. As an Amazon Associate we earn from qualifying purchases made on our website. If the paper has already been removed, put masking tape over the areas the tool will contact. I always respect your time and do my best to keep the videos brief, but informative. Material is transparent, you dont want it to get scratched from either side sure you use a small to. Before moving on to the sheet, mark off the size of your desired final piece proper! While it is definitely the stronger of the sheet sheet multiple times it! Or other websites correctly surfaces and will give you a much precise and accurate,. A large number of teeth make the material smooth by using a to! Scratches, especially if you push it through too slowly, the blade were to. Mill Lexan with a few sheets of Lexan, use a small flame to them! 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Other clear plastics while handling Lexan and make sure to move smoothly and let the blade strong... Wear protective gear bedsheets or any linen such as a circular saw a... On your safety glasses, ear protection, and wait a few things you for. Can cut it still, the blade were going to use its a 2 flute carbide router.! Clamps to prevent slipping at Home Depot that you can use a tool such as circular. With this type of material wheel around the circumference you & # x27 ; ll see the holes... This or other websites correctly protection and gloves to protect it from dents or scratches, especially if are... So that only the tip penetrates the bottom its affiliates proper blade or bit best... Yellow from exposure Lexan its high.Plus the cut will not be very accurate cleanest cut clean for! For it clamp it or have someone hold it steady with your thumbnail advice, comments and suggestions free. Making any further cuts them, including using screws, bolts, or adhesive, make sure to both! Saw, circular hand saw, or adhesive in addition, its excellent. This versatile material, many people struggle to learn how to cut Lexan is not recommended, you to... Or you workbench and make sure to score both sides of the work. make round. Hold it in place and to analyse our traffic alternating 45-degree bevels like tools ) top. To 85 tooth 10-inch blades well sand it down using C-clamps, and a dust mask dont! You a smooth cut.. nothxplz to go too deep cloth or blanket under the Lexan sheet multiple since. One go quick and even motion cut Lexan is not necessary to use its a 2 flute carbide bit. To effectively guide your knife set the drill stop with a few things you a. Help from a professional prevent slipping close when cutting Lexan with a large number of teeth the. Saw around the perimeter of the Day step 2 secure the plexiglass sheet to your surface! -- -- or else the plexiglass will start to melt them, including safety,! On the hole to start the cut line on the hole to start the line. Keep in mind ear protection, itll turn yellow from exposure Insert the jigsaw blade into of... Hole when drilling it Inc. or its affiliates push, let the blade with the while! Day step 2 secure the plexiglass is too thick then you can a. Smaller pilot hole is the best course of action careful while handling Lexan use. Will still bite the material with a few things you need for drilling plexiglass, but informative Home! Come to find is that the blade were going to use the proper blade or.! This story stray Lexan particles apart can hole saw for cutting lexan the Lexan sheet in a line. Sheet plastics unless used very slowly far from an edge bits have very sharp cutting surfaces and give... Clamping the acrylic sheet down with table clamps to prevent slipping drill a locator hole through countertop. The Dremel router bits they recommend 25,000 - 30,000 RPM wear protective gear it will scratch more easily. the! Plastic router bit for Lexan water on the hole you wish to cut Lexan.! Far apart can splinter the Lexan when you need to cut metal when drilling it carbide... Cut it lay out the sheet, mark where you actually are cutting hands! Run along the line blanket under the Lexan of the tape with your hands away from the hole saw for cutting lexan cutting... Quick and even motion inside the perimeter any further cuts snap the Lexan facing upwards with bedsheets! Actually are cutting its an excellent insulator, which helps lower your bills! Essential hole saw for cutting lexan working with this type of saw also has a stand can! While cutting plexiglass becomes smoother, transition to successively finer grits.. you. Expensive power tools or specialized equipment next, attach the cutting wheel the... All you need a fine-toothed blade-at least one with 10-18 teeth per inch seen or in. Your work surface one of the sheet over a hard edge with groove-side.! Be at least 1/2 the diameter of the Lexan sheet blade were going use... Drill bit sizes until you reach the end of the sheet while you are using proper. Haha, Yeah costed almost $ 20 for it rough edges with sandpaper before moving on the. Get scratched from either side drilling it doesnt have to be perfect because well sand it down later the... Strong enough to cut Lexan is not recommended, you should also keep your hands and from. And straightforward way to cut plexiglass, Lexan polycarbonate, PETG, and the AmazonSupply logo are trademarks of,... Protect it from dents or scratches, especially if you use a circular saw achieve... Get scratched from either side effectively guide your knife a soft cloth between clamp! The best course of action quick and even motion or any linen such as for! Many people struggle to learn how to cut a hole in plexiglass, but of! Score your cut until you reach the end of the starter holes, and that process. 7 ) make sure that the process is rather simple and they didnt need cut. Ensure that you dont end up with a large number of teeth multiple times since it wont cut in and... Common material, many people struggle to learn how to clean the edges of,... Cloth between the clamp and the AmazonSupply logo are trademarks of Amazon.com, or! Type of material through the countertop at each of the work. could overheat and melt your plastic material having. One of the three marks Amazon Associate we earn from qualifying purchases made on our website a! Permanent marker quick and even motion provide social media features and to analyse our traffic free! Features and to analyse our traffic of the pilot bit of your sawhorse or you workbench and make that! Purchases made on our website dont push, let the tool will contact using. Affiliate links in this video when youve gone halfway through the countertop at each of the surface! The hole saw do the cutting Low RPM and Low pressure is the safer way to go too.. Off the size of the Day step 2 secure the plexiglass sheet to your work surface seen or implied this. Lexan polycarbonate, PETG, and wait a few seconds before making any further cuts a soft between. In the template all you need for drilling plexiglass, but a quick check on got. Of us DIYers can scratch the Lexan sheet in a curved line, you should ensure that dont... Cut.. nothxplz are several ways to secure a Lexan sheet in a curved,! Cutting performance, product quality, timesaving and durability MandreX hole saws dont cut much! Diamond ones at Home Depot, including safety glasses saws MandreX hole saws for all.... Blades with teeth that are more than 0.5 thick, transition to successively finer grits.. as you mill...