I need to cut a piece of Lexan in half then trim it rounding the edges into an oval. What method has proven to be best? Jig saw with fine blade? Can I expect it to splinter or crack, will taping the edges help? Any thoughts. Jeff
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You didn't say how thick it was...
but for all but the thinnest of lexan, I've used a table saw with a fine tooth carbide blade. (these are sometimes called a 'plywood blade') A jigsaw will work, but your chances of cracking the material are a lot greater and it's pretty hard to hold a straight line. Also, if you do use a table saw, you'll likely have some melting of the material at the cut, so either go real slow or cut wide by about 1/8" and then sand to final dimension. For the rounded corners, I'd probably use a table sander or just mount a sanding disk in the table saw (basically the same thing) and finish them by hand. A table router would also do the trick. You don't really need to tape the cut to prevent chipping, but its easier to draw your lines on the tape and then start cutting. Hope that helps, Jeff
but for all but the thinnest of lexan, I've used a table saw with a fine tooth carbide blade. (these are sometimes called a 'plywood blade') A jigsaw will work, but your chances of cracking the material are a lot greater and it's pretty hard to hold a straight line. Also, if you do use a table saw, you'll likely have some melting of the material at the cut, so either go real slow or cut wide by about 1/8" and then sand to final dimension. For the rounded corners, I'd probably use a table sander or just mount a sanding disk in the table saw (basically the same thing) and finish them by hand. A table router would also do the trick. You don't really need to tape the cut to prevent chipping, but its easier to draw your lines on the tape and then start cutting. Hope that helps, Jeff
I have had good luck cutting different shapes using this technique. After cutting in half I mask off the "cut" line and the I score the line through the masking tape, you have to mark it any way, then using a fine blade in a jig saw, sabre saw or band saw carfully cut just outside the line. Then it is just a matter of using a fine file or sander to fine tune the cut.Good luck. Bill s/v So Fuch Mun
Thanks for comments
It is 1/4". I have used a router with success on formica and wondered if it would work. Scoring a line is a good idea with the jig. Thanks for the input. Jeff
It is 1/4". I have used a router with success on formica and wondered if it would work. Scoring a line is a good idea with the jig. Thanks for the input. Jeff
I used a roto/zip. It works best for me, no breaking whatsoever and you can use it for many other projects as well. I found it also works great for cutting fiberglass. The local Lowes the have a few on a sale table everyday. good luck.
Table, radial arm, band and scroll
Jeff: My experience with these plastic products is that they cut them with almost any saw. For the straight cuts something like a Table Saw or Radial Arm Saw work well (use a plywood or very fine blade). If you need to cut broad curves a Band Saw should work OK. For smaller radius cuts a scroll saw should work well. If you need to drill near the edge, I would suggest that you use a tappered bit to prevent cracking.
Jeff: My experience with these plastic products is that they cut them with almost any saw. For the straight cuts something like a Table Saw or Radial Arm Saw work well (use a plywood or very fine blade). If you need to cut broad curves a Band Saw should work OK. For smaller radius cuts a scroll saw should work well. If you need to drill near the edge, I would suggest that you use a tappered bit to prevent cracking.
Polycarbonates
Jigsaws are good, slower speed, fine blade. Don't worry about cracking with the saw, this is not the same animal as acrylic. I've cut 1/2" with no problem. Regards, Jim
Jigsaws are good, slower speed, fine blade. Don't worry about cracking with the saw, this is not the same animal as acrylic. I've cut 1/2" with no problem. Regards, Jim
Everything that has been said...
and if you just need to round the edges and have access to a belt sander, you can do the job there. It is quick and clean. You can grind and sand smooth at the same time. I've done it many times with woodworking projects such as bird feeders with poly or plexiglas parts. It will cost you a belt unless someone has an idea how to remove the melted plastic from the belt. If you clamp the sander down onto a table, it becomes a small stationary belt sander. That's how I do it. I don't use my large belt sander because the belts are too expensive to replace when filled with plastic particles.
and if you just need to round the edges and have access to a belt sander, you can do the job there. It is quick and clean. You can grind and sand smooth at the same time. I've done it many times with woodworking projects such as bird feeders with poly or plexiglas parts. It will cost you a belt unless someone has an idea how to remove the melted plastic from the belt. If you clamp the sander down onto a table, it becomes a small stationary belt sander. That's how I do it. I don't use my large belt sander because the belts are too expensive to replace when filled with plastic particles.
Atwood lake
Jeff, We also sail at Atwood. Which boat is your's? Email me if you want. Bryon Thomas "Shore Leave" bthomasail@earthlink.net
Jeff, We also sail at Atwood. Which boat is your's? Email me if you want. Bryon Thomas "Shore Leave" bthomasail@earthlink.net
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