cutting lexan/ Polycarbonate

[robszar]

need to make a splash guard in my canopy to prevent salt creep on my bulbs, thinking about using 1/8 lexan. anyone every use it? is it easy to cut? was thinking about using a jigsaw

 

[first-chevalier]

Jigsaw will give you a rough cut and not very smooth edge unless you're really careful/good with one. I've been cutting my 1/8 lexan/plexiglass on my 10 inch contractors table saw and works well with the base 40 tooth blade they sent me. I'd suggest no matter what you cut it with use a blade designed for finishing cuts and not ripping. Just my two cents.

 

[fourth horseman]

you can cut with a jigsaw but you have to go real slow or the blade will heat up and melt the stuff. as for rough edges just take a plumbers torch and make a few passes a couple inches away it will smooth it out and make it clear. i have always used a skill saw with a fine tooth blade. just support both sides of the plexi so it doesn't chip. practice on the pieces you cut off with the torch it takes alittle practice. i have even removed scratches this way.

 

[robszar]

ok, i have a table saw i just need to buy a finishing blade..that is probably best

 

[robszar]

i just checked the priced on saw blades and there min $50. I'll pass. back to the jig saw idea....

 

[fourth horseman]

use a down cut blade fron home depot. they only cut on the down stroke. that way it won't pick up on the lexan on the up stroke and slam it back down. the stroke has to be real slow or the lexan will melt back onto itself. good luck.

 

[Acrylics]

Do not mistake Lexan for acrylic. The same rules just don't apply as they are very dissimilar materials. In some ways, Lexan and other polycarbonates are more forgiving as they do not melt at all like acrylic, you can get it to melt but not nearly like acrylic.
You do not want to use a torch on this stuff, does not polish like acrylic, just sand it after cutting.
But do be very careful, polycarbonate is very soft and gets much "grabbier" than acrylic and can be dangerous to work with because of this.
It's great stuff, very durable, and all that but one must be a little more careful. With acrylic, if a piece "gets away" from you, it'll just crack off, not at all the case with Lexan - it can take you with it.

Good luck and be careful,
James

 

[Bergovoy]

Depending on how much you are cutting, you can cut the stuff ont he table saw with a brand new blade, (carbide tipped), with little to no problem Just feed slowly, set the sawblade depth to just a skosh above the thickness of the material you are cutting, and good luck.

Bill

 

[BruiseAndy]

If it's 1/8" why not just score and snap?

 

[Acrylics]

Lexan (polycarbonate) does not snap like acrylic, it's far too soft.

James

 

[woodymac64]

Dewalt Circular Saw Blade ...

Dewalt Circular Saw Blade ...

Just picked one of these up at Lowes tonight. It's a 7 1/4" dia. blade (hollow ground) with a 5/8" arbor made to cut plastics and laminates. I used it to cut through 1/4" acrylic on my table saw with no problems (actually made real nice cuts; I made sure to tape the areas that were to be cut - no chipping or crazing at all!). It lists for $8.97. I think I've also seen them at Home Depot for about the same price. Also routed some of the rough edges using double fluted router bits for smoothing and finishing of the edges; worked like a charm!

Now I'm finally geared up and ready to fabricate my internal sump! Sweet Nirvana!

Hope this helps you out,
Woody

 

[robszar]

nice, thx

 

[dga]

a "tile cutter" jigsaw blade. very smooth cuts. no chipping even on 1/8" best to have a variable speed and set to low. this blade does not use teeth but carbide dust...

 

[fourth horseman]

well then lexan that i have scored and snapped and used a torch on must not have been lexan. guess the manufacturer didn't know what he was making when he put the label on it.

 

[Acrylics]

<a href=showthread.php?s=&postid=9138274#post9138274 target=_blank>Originally posted</a> by fourth horseman
well then lexan that i have scored and snapped and used a torch on must not have been lexan. guess the manufacturer didn't know what he was making when he put the label on it.

soo what did you work with? Lexan or Plexi? you seem to interchange the two in a previous post. Can't have both...

 

[fourth horseman]

i've worked with both in many thicknesses from bulletproof teller windows to sneezeguards at starbucks. i am building a 14000 gallon saltwater and 20000 freshwater aquarium now. sorry i said plexi in my earlier post i will try to watch and be more careful so i don't confuse you