cadebytiger
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| posted on 22/8/06 at 10:44 AM |
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Cutting Lexan
Googling seems to bring up alot of different ways to cut lexan. non of these agree with each other.
Has anyone done this. I need to cut from a sheet so i was thinking jigsaw but i am worrid that this might melt the plastic
Any pointers from people who have already done this??
Thanks in advance
Rupert
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graememk
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| posted on 22/8/06 at 10:47 AM |
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i used a jig saw but there again i'm the same guy that used a normal grinder to cut an ally sheet .
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awinter
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| posted on 22/8/06 at 10:57 AM |
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you can cut polycarb with a jigsaw, make sure you use a plastic cutting blade with small teeth. You may fine the sheet weld itself back together after
you have cut it. May wanna try some tin snips.
Allan
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cadebytiger
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| posted on 22/8/06 at 11:03 AM |
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I would use tin snips but it is 6mm thick. Forgot to say that! Do i need a jigsaw with a variable speed?
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Bluemoon
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| posted on 22/8/06 at 11:30 AM |
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For persepex you need paper/plastic sheet on the top and bottom, I think (memory may not be quite correct!) this stops the plastic melting and welding
behind the cut. Maybe the same for lexan? As said use a fine blade.
Check it works on a peace that dose'nt matter first!
Dan
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RazMan
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| posted on 22/8/06 at 12:10 PM |
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Put masking tape along the cut line (top & bottom) and use a fine jigsaw and take it very slow - does the trick for me 
Cheers,
Raz
When thinking outside the box doesn't work any more, it's time to build a new box
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cadebytiger
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| posted on 22/8/06 at 12:17 PM |
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great thanks!! Will do that!
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cadebytiger
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| posted on 22/8/06 at 12:19 PM |
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just one more question then. Should i take the protective plastic off and then put masking tape on??
Thanks
Rupert
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JP32
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| posted on 22/8/06 at 12:59 PM |
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I use lexan for safety glass on the special equipment we are building (professional). When we cut Lexan leave the masking foil on the lexan when
cutting! Masking tape is only to protect the lexan for scratching and to mark the dimentions.
We use a normal jigsaw, slow speed, jigsaw origional used to cut wood.
Regards, JP
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the_fbi
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| posted on 22/8/06 at 06:07 PM |
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I used a normal reasonably rough wood blade in a jigsaw with no issue at all.
Was a 2 speed jigsaw on slower setting, no melting, no problems.
It was 6mm Perspex which I can't see being that much different to lexan.
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chrisf
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| posted on 22/8/06 at 06:49 PM |
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I too will need to cut some lexan in the near future. My thought was to use a bandsaw with a metal cutting blade. Will this work? After the plastic is
cut, is a long file used to smooth the edges? Seems like it would still be rough. Do you typically sand it down through the grits and follow up with a
polish?
Whew! Sorry for all the questions...
--Chris
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Peteff
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| posted on 22/8/06 at 07:06 PM |
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My jig saw runs so slow you can count the strokes on the first speed. I used a medium wood blade as the metal blades left a lot of debris that melted
back together behind the cut. I cleaned the edge with emery cloth rubbed along not across
yours, Pete
I went into the RSPCA office the other day. It was so small you could hardly swing a cat in there.
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timmy
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| posted on 23/8/06 at 01:35 AM |
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You can even cut this stuff with a circular saw with small teeth.
But personally I would go for a jigsaw with a normal wood blade. Use coolant if you need to stop the plastic trying to weld itself back together.
Lexan (polycarbonate) is very durable so don't worry too much about breaking it. Perspex (acrylic) is a different animal and care needs to be
taken cutting it.
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cadebytiger
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| posted on 23/8/06 at 08:50 AM |
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Wow! Thanks for the help! Will be cutting tonight so finggers crossed
Rupert
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chrisf
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| posted on 5/10/06 at 09:13 PM |
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How did this turn out? Month's afterward, I finally ordered my lexan
--Chris
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