Cutting Lexan

[rustnpede]

What are some diferent ways to cut Lexan without using special tools?

Im making the esc and battery trays for my revo, using 3/16" lexan, a sharp knife and the score/snap method. Ive made 3 cuts that took more effort than I thought would it would take. Ive seen lexan knives in the hardware store. would they make the task any easier?

[wallot]

get lexan scissors. u can get straight or curved and they cost about $10 and cut lexan like butter

[BrianG]

I've never had trouble with the score-and-break method. I score each side twice to make sure the score is deep enough, put the excess piece over a flat corner, clamp it down, and snap it off. Every once in a while, there might be an imperfection that I'll touch up with a dremel, but I'm kinda anal about having straight edges and perfectly rounded corners...

@Wallot: Can lexan scissors cut thicker stuff, like 1/8" +?? Are you thinking body lexan scissors?

[jimbob]

how thick are we talking in mm around 5??

i got some 6mm plastic that im using for a servo mount and atm it keeps melting when i go to cut it, so any advice will be much appreciated here :027:

[GorillaMaxx360]

i like to use a durbro lexan sizzors. for just 12 bucks at your lhs you get the sizzors and a body reamer. these are good but for small indintations they are hard to cut. yesterday i used a dremal to cut out my body. very time consuming but the result was a perfect hole in the back of my 18t body.

[rustnpede]

Not lexan bodys. Lexan sheets. Like plexiglass.

Originally Posted by BrianG

. . .I score each side twice to make sure the score is deep enough, put the excess piece over a flat corner, clamp it down, and snap it off. . .

I thinks thats the problem. I dont have a workbench so im doing all this on top of a wood board on my living room floor:p. Cant wait to move. I havent been scoring both sides though.

Originally Posted by jimbob

how thick are we talking in mm around 5??

i got some 6mm plastic that im using for a servo mount and atm it keeps melting when i go to cut it, so any advice will be much appreciated here .

4mm exactly. Are you using a saw? I read that your suposed to run water over the blade.

[GorillaMaxx360]

sorry man just realized it was thick lexan not the lexan the body's are made from. in this case use the scoring method, scroll saw, or a dermal with cutting wheel.

[jimbob]

im gunna try the snapping method :032: wish me luck

ya it defo needs water or something, it just starts melting, problem is trying to set that up lol no idea how to do tht... o well only straight cuts for me now so hopefully it will be ok

what kinda knife you all using??

[wallot]

well I use lexan body scissors for cutting anything plastic I need and some stuff is 3mm (about 1/8"). for thicker material i would try scissors for metal.

[redhatman]

For my revo battery mounts I used about 3/16" plastic cut by my dremel with cutoff discs. I then rounded out the edges with a grinder.

[BrianG]

If using a saw, you have to use a serrated blade at low speed if you don't want to melt the plastic. Also, take small "bites" and back off to let the plastic cool. You could also try a miterbox, but the score and snap method seems to work the best for me and doesn't require a lot of work - just a sharp knife...

[rustnpede]

Originally Posted by redhatman

For my revo battery mounts I used about 3/16" plastic cut by my dremel with cutoff discs. I then rounded out the edges with a grinder.

I think i might try that. Edges with a bullnosed finish would be nice.

[redhatman]

Originally Posted by rustnpede

I think i might try that. Edges with a bullnosed finish would be nice.

Yeah, here is mine as of now:

[rchippie]

Originally Posted by rustnpede

What are some diferent ways to cut Lexan without using special tools?

Im making the esc and battery trays for my revo, using 3/16" lexan, a sharp knife and the score/snap method. Ive made 3 cuts that took more effort than I thought would it would take. Ive seen lexan knives in the hardware store. would they make the task any easier?

For that thickness i use my table or ban saw, with a blade made for cutting plastic. A router works very well also.

I try to stay away from power tools when cutting plastic. I think it's more of a PITA than it's worth. If you don't want to use the score a snap method, try a hacksaw with a fine blade.