Words of advice for Lexan? Making a Kammback

[turbovr41991]

Originally Posted by Vekke

I used angle grinder with 0.8mm blade to cut that 2mm thick sheet. It worked nicely.

Do you think an angle grinder is better than scoring it with a blade?

I think if I did this for a living, scoring it would be better. But since I am a novice, the angle grinder might be bet best approach. Similarly to tile cutting. Scoring/ snap cutting is faster and does a great job, but since I am a novie, I find a diamond plade on an angle grinder seems to be easier for me and I waste less tiles!

[kach22i]

I suggest you wear hearing protection as well as eye protection when using power tools.

I have a pair of compact (black color) Stihl ear protection muffs, much better than anything I could have bought at the local stores. I found them on the side of the road while walking, some lawn mower guy must have lost them.

Also beware of fumes from burning foam fumes, if you start getting silly or dizzy, clear the room.

When you cut any material at high speed there could be fumes. We all know what burning wood from a circular saw and hot metal while grinding smells like, right?

[Vekke]

PC is not so easy to score. if this means making a cutting line with box knife and bend it broken. PC does not broke when you bend. That works for acrylic but still tricky if you have to cut over 1 meter lengths. One cut to every 1mm thickness so 3 for 3 mm thick acryl.

jigsaw does not make so straight line easily and you easily scrape the clean surface when the masking plastic gets hole when you have to push the saw towards the sheet.

If you only have to cut only straight circular saw/table saw works great for PC. For acrylic you need to cut over 3mm thick sheet. On smaller thickness it tears the edge quite easily if you dont have very sharp saw blade.

[RiderofBikes]

Using a Jigsaw at a lower saw rate of any TPI blade with PolyCarbonate works well since, it does not break easily if at all if your needing a slight curved shape or edge to contour whatever it is your trying to match it with. Acrylic is best scored, but if you get it thick enough, you might be able to use the jigsaw again with a finer TPI blade with it against a VERY sturdy backing, this also applies to Lexan as long as it has sufficient thickness.