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Cutting Lexan - last minute advice

post #1 of 21
Thread Starter 
Okay, I am going to start cutting the panels for my case tonight. Well hoping to at least get the top and bottom panels cut.

Any last minute advice before cutting the lexan?

I am going to clamp a board down as a straight edge and use a jig saw to cut the panels. The bottom and top are both 18" x 18" x 1/4" so should be straight forward.... I hope
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post #2 of 21
Make sure you use the right blade (I'm sure you knew that) It should say "plastic, wood" on it. And be ready for lexan dust =] it sux
    
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post #3 of 21
Make sure not to saw your fingers off.
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post #4 of 21
If the lexan starts vibrating during the cuttingprocess, stop for a few seconds because you´ll crack it for sure.
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post #5 of 21
Use a fine tooth blade on it to prevent chipping. Use a slow speed and take your time. Make sure to tape down your area before starting, you don't want to scratch the lexan with the base of your jigsaw.
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post #6 of 21
Measure twice cut once.

Accidents only happen when you don't think, take your time and think/dry fit everything before you make a cut or anything.
    
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post #7 of 21
Pretty much everything has been covered.
  • Measure twice, cut once.
  • Tape over where the saw will touch the surface, unless it already has a covering adhered to the surface.
  • Use a sharp (new) blade for a good finish.
  • Make sure the guide is clamped firmly, but not so tight as to crack the polycarb.
  • Let the blade do the cutting, don't force the saw forward.
  • If it starts vibrating, stop and back it out.
  • Have a vacuum ready.
post #8 of 21
Thread Starter 
thanks all, great tip and advice. I am a little nervous about making the first cuts as I have never worked with lexan before.
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post #9 of 21
It might be a good idea to make a cut outside your finish cut first just to get a feel for it and get more confidence in what you are doing before doing the finish cut.
post #10 of 21
Thread Starter 
Quote:
Originally Posted by RyGuy View Post
It might be a good idea to make a cut outside your finish cut first just to get a feel for it and get more confidence in what you are doing before doing the finish cut.
I wish I would have done that.

The pieces I tried still might be salvageable if not my case will now be a 17" x 17" x 17" cube instead of 18" x 18" x 18"
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Home built MacPro
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