hondajt

Yeah. I bought some clear plexiglass at HD. My dremel is at my gf's house.

It cracks really easy! I tried high & low speeds with a jigsaw, router, bandsaw and hacksaw (electronic, don't ask). All of them sucked.

Here is what I have so far, but I will hopefully finish it tomm night with my dremel.

I plan to cut a square hole in it for my radiator also.











I will have the side completely sealed, other than the hole for where the radiator is mounted currently (the last picture).

See the cracks? This sucks to work with.

A-E-I-Owned-You

Leave it as is and turn the case into a work of art focusing on destruction.

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Socom

Well first, I would've made the trip for the dremel. I also would have used some 3/16" plexi if it was me.

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CattleRustler

I like this idea
but seriously, keep practicing, you'll make it

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A-E-I-Owned-You

+1
Even in failure comes experience.

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voodoo71

Hey. Did you use any kind of painters tape to cover the plexi-glass. I have cut a couple windows and found that the tape helps to keep the plexi from cracking.

HuffPCair

Samething happened to me. I just got the piece into a position you cant see the cracks unless the door is off lol.

LiNERROR

did you use an acrylic blade or a wood one? anyways, straight cuts on thin work like yours should be cut like glass... scribe it and break it...

reciprocating blades are available to cut acrylic... if you can't find the right blade use blades designed to cut aluminum or copper. fine toothed 18TPI+, same height, evenly spaced, little or no set...

for circular saws, high speed hollow ground blades, no set and at least 5TPI+... triple chip tooth carbide blades will give the smoothest cuts....

for routers... double fluted bits for edge routing and single fluted bits for inside circle routing... it is critical to avoid all vibration, even the slightest vibrations can cause fractures during routing...

did you put this on something to cut? or just extend it off your workbench? you need to support your piece... get a piece of plywood... set your blade to 1/4th of an inch, make a groove... now set your acrylic over this when you cut it... with your blade extending 1/8th of an inch through the acrylic...

do a little research on working with acrylic... and practice... you're not going to get perfect results your first time cutting improperly with the wrong tools...

you don't want to melt the work piece...

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ericld

Use higher rpms. It actually melts as it cuts. And keep it as straight as possible. A thicker piece of acrylic would not crack as easily either.

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fstfrddy

Forget plexiglass and get Polycarbonate sheet. It is much easier to work with and much more crack resistant. It's more expensive but at least you wont be throwing it away.

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