Need advice on cutting/gluing acrylic sheet

[Dionaea]

Greetings, DIYers!

I want to make a simple acrylic screen, the basic idea of which is pictured below. The screen, made of black acrylic, will go on top of the tank to block light from my 8x39 Watt Tek Light from my living room. I plan to paint the front side with metallic paint (Krylon?) to match the Tek Light.

My problem is the man I would have bought pieces like this from in the past (LFS owner and good friend) recently passed away, and now I am at a loss as to how to get these pieces. I do not know how to cut acrylic, especially with this degree of accuracy (to the 1/8"). Are there online sources for pre-cut acrylic? If not, how difficult would such a job be, and what should I use?

Also, I have glued acrylic into sumps and such before, but hints on the best way to glue the pieces as pictured would be appreciated as well.

Let me know if more details are needed. The sides are intentionally shorter than the front by 1/8".

Thank you in advance for any help!

 

[dzeadow]

most places will cut pieces to your dimensions for what they call a "cut" charge. I'm pretty sure the charge is by the piece.

As for gluing, there's a few different ways to do it, the pins method, etc. If you go onto youtube.com and search for "tap plastics" they have quite a few online videos for cutting, gluing, bending, etc. acrylic. HTH

 

[dzeadow]

i guess giving websites would have helped:

interstateplastics.com
estreetplastics.com
rplastics.com
mcmaster.com
freckleface.com

most will have a quote feature where you can email them and ask how much it will cost for the sheets and the cuts.

 

[Dionaea]

Danny,

Thanks a heap for the links and tips! The videos are top notch.

I do not have a table saw, but I do have a band saw. If I use a guide, will this make a smooth enough cut to allow for solvent welding, or should I have someone with a better saw cut them?


Thanks again!

 

[not_sponsored]

You can use a band saw but it will probably dull your blade. Make sure you stop often to cool down the blade or your will start melting the acrylic. You will also have to finish sand it with something to make sure it's a level edge.

 

[dzeadow]

Your best bet is to use a router, even a cheap router, with a flush cut bit on it. I just made a square skimmer box, and fortunately I've got a 3.25hp router that zipped right through the stuff, even when I stacked 3 sheets at a time. Using the router will allow you to make sure it's square vs. a used table saw sometimes the fence isn't set up square and you could have problems. If you use your band saw, make sure you have a gritty sand paper ready on a sanding block, I'm sure since the thing won't be able to cut fast enough that it'll melt the acrylic like stated before. Doesn't hurt to try a scrap piece though to see what results you get. Even my mitre saw would melt it if I was going to slow. If at all possible I'd find a router w/ a flush cut bit and a router guide, OR have the company you're ordering from do the cuts. If you need help w/ figuring out the router/guide/bit thing, let me know.

 

[dzeadow]

Of course, you're only going to need 2 glueable sides it looks like, so maybe it'd be easier to use your band saw for everything, and make sure you sand the edges you are gluing w/ a sanding block and make sure you don't round the edges over. For something so simple, I wouldn't worry if it didn't turn out too perfect, it's not like it's holding water or anything!

 

[Dionaea]

I am interested in the router idea, but I don't want to invest alot of $$ in a tool I am going to use once or twice a year. I have seen some plunge-type routers at Harbor Freight for like $40. Is this the type I would need, or do I need the table type for stuff like this?

Or, rather than completely having to completely explain routers to a neophite like me, is there a reference out there I should be reading? I totally welcome your advice, but I don't want to waste your time if I can read it somewhere and ask any questions I still have later.

Thanks again for all of your valuable info!

 

[dzeadow]

It'll probably work, is it a 1hp one? You wouldn't need the table. I used the table saw to cut the stuff to approximately the size I needed +1/8, then used the router w/ template guide on it to cut the extra 1/16" on both sides off. W/ a 1/2" bit and 1" template guide, the measurements are easy. I guess it all depends on the size router and what template guides will fit on it. I don't mind answering questions, so ask away! I just hope I can explain what you need in terms that are easy to understand!

 

[chaffey]

Danny - I am thinking of getting a router and a table saw to do some acrylic cutting/trimming work, can you suggest a good brand and value to buy at home depot ? thank you in advance.

 

[dzeadow]

the table saw isn't going to be that big of a deal if you're just going to cut acrylic w/ it, you could go fairly cheap unless you're going to be cutting big sheets w/ it, then you'd want something w/ legs and possibly an extending table. I use Rigid's mobile unit, it was $500ish.. but I think if you're doing smaller projects you could get away from going that route.

As for the router, porter cable has a pretty good brand, if you're doing thinner stuff, a 1 3/4hp would probably be fine, if you're doing 1/2", you'll probably want to beef that up to a 3.25hp, just to make sure you're spinning your bit fast enough not to get chatter. I have a big porter cable that I use for countertops that works great for cutting thicker material.. I believe it was in the $250-300 range..maybe, I can't remember, but I use a Feinn brand which is kind of a specialty brand found in true power tool stores and some lumber yards, I got a deal on it for $275.. that thing rips. Plus if you're doing a lot of work w/ it, you'll want to invest in a good carbide tipped bit that way you can get it sharpened for cheaper than having to buy a new one. But they have decent bits that will last quite a long time for like $20 out there.

 

[chaffey]

thank you for your help.