Plexiglass side door

[orion446]

What is the best method to cut a 120mm hole in plexi glass? Any help would be appreciated.

 

[Tiamat]

Not very easy. You want a Milling machine, and a circle cutting tool (looks kinda like the glass circle cutting tools you see in movies). Low RPMs on the milling machine, and piece of wood for support.

 

[orion446]

Where can I get one?

 

[DangerAardvark]

Hole saw would work too. Just remember to tape the plexi up first.

 

[Tiamat]

Originally posted by: orion446
Where can I get one?

Milling machines are in machine shops - they are very expensive. You basically have to know a machinist - or ask very nicely at your college. The circle cutting tools - i have no clue where you actually buy them. I only know this because this is what the machinist here at work used on my case.

If you use a hole saw (very easy to find like at true value or elsewhere), you have to find one large enough for your 120mm hole, and its easier if you do it on a milling machine/drill press than on a hand drill. Word really slowly, and you may want to have a flat table with pieces of wood beneath the plexi for support.

 

[stevennoland]

Get (borrow) a Rotozip and the large hole cutting attachment. I used mine to cut two 120 mm holes in my Lian-Li case. Make sure the case is EMPTY. A lot of small chips will be generated this way.

 

[Omega Ohm]

A dremmel with a multipurpose cutting bit #561 and the circle guide attachment. Don't go too fast or the plexiglass will melt.

 

[MiStErBRoc]

i say holesaw also... i used a 4 1/2" holesaw which is like 115mm something of that nature just like stated before mask everything off with tape and go slow as you dont want to melt the plexi

 

[Tiamat]

As above stated, I cannot state more than enough times how important it is to take your time. I did a rush job and it came out like crap. The plexi melted and discolored. I had to throw it away because no amount of filing would fix it. Take your time and you should get very nice results!

Good luck!

 

[orion446]

I think I am going to use a hole saw and take it real slow

 

[stevennoland]

Post a pic of your work. Good luck.

 

[MiStErBRoc]

yep good luck... look forward to the pics :beer:

 

[Omega Ohm]

Shame, I think you'll get more long term use with the Dremmel. Those things kick all kinds of ass.

 

[orion446]

Got the hole saw and it turned out pretty good, I will post a pic when I get home from work