hand-cutting HDPE (starboard) sheets

[ACBlinky]

I've been looking for starboard to line the bottom of the new tank (we're going BB). I've found a source for HDPE cutting boards, but I'll need to cut them to size by hand (or, if necessary, pay someone else to cut it).

Can any of you handy DIYers tell me if I'd be able to cut 1/4" starboard with a hacksaw? I'll need to cut 2" off the end of each, or 4" off of one (if it's easy to cut, I'd probably do both, so the line joining the two is in the center of the tank; if it's really difficult, I'll live with an off-center line).

Thanks!

 

[biodegraded]

Can you use a hacksaw? Sure, but it's far from optimal for your application. It'll be slow and tend to gum up in the kerf. Depending how generous feeling the staff at your local Orange Borg (Home Depot) are, you may be able to get it sawed there without cost. Or maybe a buck a cut. Depends how cost vs time sensitive you are.

A possible alternative is if you know someone who has a woodworking hand saw made for ripping that you can borrow. Anything from the old-time things we used before electricity was invented to a nice japanese affair that cuts on the draw. Keyword is you want rip, not cross cut. Good luck.

 

[ACBlinky]

Wow, than you, that was very specific and helpful!

I do need a couple of things at Home Depot, maybe I'll mark the boards, and then bring them along and ask if someone could cut them for us.

 

[williewilliams]

Those crazy japanese. Saws that cut on the pull. what will they think of next? By the way these saw are truly awesome, and cut very smoothly. Perfect for fine woodworking, and probally this project. Good luck with it.

 

[guezei]

Yes you can use a hand saw, however it most likely will not give you the desired edge. I would recommend trying to find a local shop that is willing to cut it for you. Or you could invest in a relatively inexpensive circular saw and strait edge for less then $150.

 

[ACBlinky]

Just to follow up, in case anyone ever has the same issue...

We went to Home Depot today, and I asked very nicely but they were unwilling to cut HDPE. Undaunted, we went to the saw/blade section, and found a little Japanese pull saw designed for 'fine woodworking' that said it would leave nice clean edges. I figured for $14.99 it was worth a shot

The straight cut was EASY, the board cut like butter. The round cut (where the board has to curve around the overflow) was difficult and didn't turn out flawlessly, but sandpaper smoothed the rough edges, and it will never be seen, especially once the edge has been siliconed to the tank bottom.

TLDR; Small, flexible pull saw did the trick very nicely

 

[SkyReef]

I cut my Starboard on a table saw. That worked just fine. I didn't find that the material melted or gunked up in any way. The kerf debris was more like black pencil shavings. Good luck.

 

[turtlespd]

If u want to finish your cut u can grind it flat on the concrete.

 

[joedc]

At 1/4" is rather use a straight edge and scribe with a razor it a whole bunch of times the lay it at the corner of a table and break it

 

[NanoReefWanabe]

I cut my Starboard on a table saw. That worked just fine. I didn't find that the material melted or gunked up in any way. The kerf debris was more like black pencil shavings. Good luck.

the material will melt and gunk up a hacksaw though, as was originally inquired about...any standard table saw blade will cut it though (24-80 tooth)

as for handsaw, i dont know if it would matter if you used a cross cut or rip saw...the material is so soft, i think either blade will cut it like warm butter...