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Cuttin' Acrylic

post #1 of 5
Thread Starter 
The case i really want , Sunbeam UFO http://www.newegg.com/Product/Produc...=SunBeam%2bUFO
has a top over the mobo half of the case. I already know my 125mm Zalman 9500A won't fit with the top shelf clearence of 120mm. With the motherboard, standoffs, and mounting bracket the cooler would be maybe 20mm over the top. So I'm thinking, what if I cut out a hole in the top and with the copper fins sticking out it would look like a muscle car!!! sweet. the only problem is I have o experience with cutting acrylic. Or anything else for that matter. My dad has a bunch of drill he uses for stuff so could someone advice me to the procedure for cutting a most likely 120mm hole in a clear acrylic plate? thanks
The Doombringer
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The Doombringer
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post #2 of 5
Got a couple of questions for you.
Do you have a jig saw?
Do you have a hole saw? about 1"
Do you have a router?
Do you want a really square hole or one with radius corners?

I had a similar idea before and if you just want a round hole I would get a hole saw the same size as your hole. I always predrill a hole for the pilot hole to avoid cracking the acrylic. Use a scrap piece of wood to back the acrylic(bracing it while drilling). Only drill half way through with the hole saw then flip over the acrylic and finish cutting the hole from the reversed side. Now you can sand that edge with 100 grit then 300 grit and last with 600 grit to remove tool marks. Last get a buffing wheel smaller than your hole and some Tripoli buffing compound to make the edge look like the rest of the edges on your case.
Edited by Gom Jabbar - 6/2/08 at 3:33pm
Destination Void
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Destination Void
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post #3 of 5
Thread Starter 
uhh, no jig saw, yeah hole saw, mebe router and its gonna have a radius cuz of the contour caused by the circular fins, heres the pics of the cooler. http://www.newegg.com/Product/Produc...8223&Tpk=9500A
The Doombringer
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The Doombringer
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post #4 of 5
dremel has 1.5" cutting disks for plastic, just thought i'd mention that since I found it out recently. Also theres jigsaw blades and bits for plastic specifically. I hear you can use a bi-metal holesaw as well just keep the rpms low
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Chuckle2Tits
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post #5 of 5
If you have a router you can get better results and a small radius corner to boot. Plus less sand is needed to remove tool marks. You will need a jigsaw or a radial cutter to precut your hole.

If you use the router you will need to make a template its not difficult it just takes some. Make a frame kind of like a picture frame. No need to secure the corners we will use two-face tape to secure the template to the acrylic while cutting. we will use the inside of the frame as a cutting guide for the ball bearing router bit. A 1/2 bit will give you a 1/4 inch radius which I think will work for you. Like I said above precut your hole about a 1/4 inch smaller than your what you want your finished hole to be this will let the router work better.

It might seem like like a lot to do but that is a nice case and think it is well worth the trouble. Let me know if you are having problems understanding and I will try and draw some diagrams.
Edited by Gom Jabbar - 6/2/08 at 4:12pm
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Destination Void
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