I built a display case from scrap wood. It has a sliding 1/16" Plexiglass window. The place where I bought and had the sheet cut, cut the sheet about 1 mm too tall. What's my best option for trimming the sheet? The sheet is about 20 x24". I need to trim the longer side. Cutting with a carpet knife is out of the question, I think, right? The only other option I can think of is sanding with a sanding block wth 80 grit. I should have bought that table saw the other day! Any ideas?
Trimming Plexiglass
- Thread starter BRZED
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Don't the car audio guys use routers?
I have used a belt sander to take a bit off on thicker pieces close to 1/4 inch.
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JHZR2
Staff member
Rand said:
Bosch Plexiglas Jigsaw blade: http://www.toolbarn.com/bosch-t101a.html...;ad=54708892214
Cut it on a sacrificial plywood board for support
Sand smooth
Lightly hit with propane torch to blend-in and smooth over edge
Cut it on a sacrificial plywood board for support
Sand smooth
Lightly hit with propane torch to blend-in and smooth over edge
I have a lot of experience cutting plexiglass with a cardboard backer on the table saw...almost anything works to keep it from chattering and grabbing the blade.
Hangfire mentioned the only finishing touch that works and it's easier than any other - flame polishing very lightly with a handheld propane torch. Takes a little practice.
Hangfire mentioned the only finishing touch that works and it's easier than any other - flame polishing very lightly with a handheld propane torch. Takes a little practice.
As I said, I should have gotten that table saw last month. Good excuse to still get it anyway. So I tried sanding with 80 grit glued to an aluminum block. I removed a 1/4 mm in about 5 minutes. I think I'll get coarser sandpaper and keep doing that. Or maybe it's time to get a laser or water jet cutter.
JHZR2
Staff member
Originally Posted By: BRZED
As I said, I should have gotten that table saw last month. Good excuse to still get it anyway. So I tried sanding with 80 grit glued to an aluminum block. I removed a 1/4 mm in about 5 minutes. I think I'll get coarser sandpaper and keep doing that. Or maybe it's time to get a laser or water jet cutter.
Find a parking lot with smooth concrete. Roll along slow in your car, in an area with nothing to hit. Open the door, press the edge to the smooth concrete and allow it to abrade.
As I said, I should have gotten that table saw last month. Good excuse to still get it anyway. So I tried sanding with 80 grit glued to an aluminum block. I removed a 1/4 mm in about 5 minutes. I think I'll get coarser sandpaper and keep doing that. Or maybe it's time to get a laser or water jet cutter.
Find a parking lot with smooth concrete. Roll along slow in your car, in an area with nothing to hit. Open the door, press the edge to the smooth concrete and allow it to abrade.
Originally Posted By: JHZR2
Originally Posted By: BRZED
As I said, I should have gotten that table saw last month. Good excuse to still get it anyway. So I tried sanding with 80 grit glued to an aluminum block. I removed a 1/4 mm in about 5 minutes. I think I'll get coarser sandpaper and keep doing that. Or maybe it's time to get a laser or water jet cutter.
Find a parking lot with smooth concrete. Roll along slow in your car, in an area with nothing to hit. Open the door, press the edge to the smooth concrete and allow it to abrade.
I'll have Cornholio test that procedure for me.
Originally Posted By: BRZED
As I said, I should have gotten that table saw last month. Good excuse to still get it anyway. So I tried sanding with 80 grit glued to an aluminum block. I removed a 1/4 mm in about 5 minutes. I think I'll get coarser sandpaper and keep doing that. Or maybe it's time to get a laser or water jet cutter.
Find a parking lot with smooth concrete. Roll along slow in your car, in an area with nothing to hit. Open the door, press the edge to the smooth concrete and allow it to abrade.
I'll have Cornholio test that procedure for me.
Sand smooth
Lightly hit with propane torch to blend-in and smooth over edge
I've done this with 1/16" clear Plexiglas.
For bests results, I get a good finish before using any flame.
1) Sand
2) Steel Wool
3) Plastic Polish
4) Then use Flame
I felt the Flame was to get better results than just polishing, not to avoid polishing all together.
Suggestion: If you use a flame to get a better finish, practice on scrap piece first.
And with any Plexiglas, the very last thing you do is remove the protective paper.
Lightly hit with propane torch to blend-in and smooth over edge
I've done this with 1/16" clear Plexiglas.
For bests results, I get a good finish before using any flame.
1) Sand
2) Steel Wool
3) Plastic Polish
4) Then use Flame
I felt the Flame was to get better results than just polishing, not to avoid polishing all together.
Suggestion: If you use a flame to get a better finish, practice on scrap piece first.
And with any Plexiglas, the very last thing you do is remove the protective paper.
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Originally Posted By: BRZED
As I said, I should have gotten that table saw last month. Good excuse to still get it anyway. So I tried sanding with 80 grit glued to an aluminum block. I removed a 1/4 mm in about 5 minutes. I think I'll get coarser sandpaper and keep doing that. Or maybe it's time to get a laser or water jet cutter.
Some really interesting suggestions here....
I use a sharp cabinet scraper. Leaves a much smoother edge than 80g paper and removes material faster. Chuck the plexi in a padded vise to hold it rigidly. You can also buy a scraper especially made for this purpose.
As I said, I should have gotten that table saw last month. Good excuse to still get it anyway. So I tried sanding with 80 grit glued to an aluminum block. I removed a 1/4 mm in about 5 minutes. I think I'll get coarser sandpaper and keep doing that. Or maybe it's time to get a laser or water jet cutter.
Some really interesting suggestions here....
I use a sharp cabinet scraper. Leaves a much smoother edge than 80g paper and removes material faster. Chuck the plexi in a padded vise to hold it rigidly. You can also buy a scraper especially made for this purpose.
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