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albertakolbmk3
Joined: 13 Jun 2009
Posts: 69
Location: Innisfail, AB
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 Posted: Wed Jan 20, 2010 2:15 am Post subject: Best way to cut lexan |
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What is the best way to cut lexan. Knife, bandsaw, jigsaw. I'm just about ready to to start cutting my new lexan... never done it before. Any advice would be appreciated.
Tony
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Tony B.
Kolb MKIII C
Rotax 582
C Gearbox 3.00:1
WD 66" 3 Blade Prop |
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rickofudall
Joined: 19 Sep 2009
Posts: 1392
Location: Udall, KS, USA
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| Posted: Wed Jan 20, 2010 2:54 am Post subject: Best way to cut lexan |
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| Quote: | From GE:Lexan® polycarbonate sheet products can be cut
and sawn easily and accurately using standard
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workshop equipment. Circular saws, band saws,
jig saws and common hacksaws can all be used
successfully. However, certain important guide-lines
should be followed. General guide-lines are listed
below with specific recommendations outlined in
each cutting section.
• The sheet must always be securely clamped
to avoid undesirable vibration and rough cut
edges.
• All tools should be set for cutting plastics with
fine toothed panel blades.
• The protective masking should be left on the
sheet to prevent scratching and other surface
damage.
• When finishing the edges of all Lexan sheet
products should be clean and free of notches.
• If possible swarf and dust build-up should be
blown away with a compressed air supply.
NOTE: Lexan is often used as a generic term. It is not, it's a specific formula of polycarbonate, which IS the generic. Whatever you buy, if it doesn't say Lexan on the covering paper, get that manufacturers cutting recommendations as some formulations are more brittle than others.
Rick Girard
On Wed, Jan 20, 2010 at 4:15 AM, albertakolbmk3 <cheriebraun(at)xplornet.com (cheriebraun(at)xplornet.com)> wrote:
[quote]--> Kolb-List message posted by: "albertakolbmk3" <cheriebraun(at)xplornet.com (cheriebraun(at)xplornet.com)>
What is the best way to cut lexan. Knife, bandsaw, jigsaw. I'm just about ready to to start cutting my new lexan... never done it before. Any advice would be appreciated.
Tony
--------
Tony B.
Kolb MKIII C
Rotax 582
C Gearbox 3.00:1
WD 66" 3 Blade Prop
Read this topic online here:
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phoenix(at)ja2.so-net.ne.
Guest
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| Posted: Wed Jan 20, 2010 3:25 am Post subject: Best way to cut lexan |
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Hi Kolbers
Just adds my fragment.
Ultrasonic cutter also available with easy and clean way.
Here is Youtube demo.
http://www.youtube.com/watch?v=QaejhHMbH0Y
And one of Ad.
http://www.nalex.co.jp/e-cutter.html
Really like a cake.
But counter is expensive.
On 2010/01/20, at 19:53, Richard Girard wrote:
[quote]>From GE:Lexan® polycarbonate sheet products can be cut
and sawn easily and accurately using standard
workshop equipment. Circular saws, band saws,
jig saws and common hacksaws can all be used
successfully. However, certain important guide-lines
should be followed. General guide-lines are listed
below with specific recommendations outlined in
each cutting section.
• The sheet must always be securely clamped
to avoid undesirable vibration and rough cut
edges.
• All tools should be set for cutting plastics with
fine toothed panel blades.
• The protective masking should be left on the
sheet to prevent scratching and other surface
damage.
• When finishing the edges of all Lexan sheet
products should be clean and free of notches.
• If possible swarf and dust build-up should be
blown away with a compressed air supply.
NOTE: Lexan is often used as a generic term. It is not, it's a specific formula of polycarbonate, which IS the generic. Whatever you buy, if it doesn't say Lexan on the covering paper, get that manufacturers cutting recommendations as some formulations are more brittle than others.
Rick Girard
On Wed, Jan 20, 2010 at 4:15 AM, albertakolbmk3 <cheriebraun(at)xplornet.com (cheriebraun(at)xplornet.com)> wrote:
[b]
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mdnanwelch7(at)hotmail.co
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| Posted: Wed Jan 20, 2010 7:14 am Post subject: Best way to cut lexan |
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> What is the best way to cut lexan. Knife C bandsaw C jigsaw. I'm just about ready to to start cutting my new lexan... never done it before. Any advice would be appreciated.
Tony C
I cut Lexan with my handheld Makita grinder C with a 1/16" thick cut-off blade. By using this method C the only thing that touches the surface is just the blade. That way you don't risk scratching the Lexan's surface in the cutting process (like with the base of the saw).
I find there is a "sweet spot" in the cutting speed. Too slow C and you melt the Lexan C which leaves a LOT of cleanup with a handheld sander. Too fast C and the cut is quite rough. Again C more work with the sander.
By practicing on a scrap piece of Lexan C you'll see what I mean. Finding the right speed to make the cut leaves just a small job of sanding clean-up.
Undoubtedly C there are other ways to cut Lexan C but that method works best for me.
Mike Welch
MkIII CX
Hotmail: Trusted email with Microsoft0706/direct/01/' target='_new'>Sign up now. [quote][b]
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herbgh(at)nctc.com
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| Posted: Wed Jan 20, 2010 7:39 am Post subject: Best way to cut lexan |
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John Hauck
Joined: 09 Jan 2006
Posts: 4639
Location: Titus, Alabama (hauck's holler)
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| Posted: Wed Jan 20, 2010 7:49 am Post subject: Best way to cut lexan |
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I use aviation tin snips. Works really easy on 1/16" polycarbonate. A
little tougher on 1/8". Finish edges with mill file and sand paper.
john h
mkIII
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John Hauck
MKIII/912ULS
hauck's holler
Titus, Alabama |
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NeilsenRM(at)comcast.net
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| Posted: Wed Jan 20, 2010 8:23 am Post subject: Best way to cut lexan |
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I have also used tin snips with good success. I wouldn't recommend doing
this when the lexan is cold, its seems to get brittle. Again cold is a
relative term. Florida cold 50-60 might be fine. Michigan cold 0 degrees or
less you might have problems getting a good cut.
Rick Neilsen
Redrive VW powered MKIIIC
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whiskeyvictor36(at)aol.co
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| Posted: Wed Jan 20, 2010 8:11 pm Post subject: Best way to cut lexan |
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In a message dated 1/20/2010 5:15:40 A.M. Eastern Standard Time, cheriebraun(at)xplornet.com writes:
| Quote: | What is the best way to cut lexan. Knife, bandsaw, jigsaw.
Tony,
In the past, I used a hacksaw blade, just the blade, wrapped in a rag and held in my hand. It took a long time to make the cut. Was hard to follow the line, left a rough edge and made a lot of dust/dirt.
Now I cut it with my shears. The 12 inch size is a little hard to squeeze so if you have a larger size it would be easier. It's easy to follow the line, It cuts clean and needs very little sanding or smoothing. Test it on a small piece and you will be amazed at how well it cuts.
Bill Varnes
Original Kolb FireStar
Audubon NJ
Do Not Archive
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[quote][b]
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albertakolbmk3
Joined: 13 Jun 2009
Posts: 69
Location: Innisfail, AB
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| Posted: Thu Jan 21, 2010 5:35 am Post subject: Re: Best way to cut lexan |
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John,
Tried the snips on an old piece and it does work quite well... I think that is the way I'm going. No mess is always good.
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Tony B.
Kolb MKIII C
Rotax 582
C Gearbox 3.00:1
WD 66" 3 Blade Prop |
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by0ung(at)brigham.net
Guest
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| Posted: Thu Jan 21, 2010 11:32 am Post subject: Best way to cut lexan |
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What is the best way to cut lexan. Knife, bandsaw, jigsaw. I'm just about
ready to to start cutting my new lexan... never done it before. Any advice
would be appreciated.
Tony
I used a hand held grinder with an abrasive wheel,
Boyd Young
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racerjerry
Joined: 15 Dec 2009
Posts: 202
Location: Deer Park, NY
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| Posted: Fri Jan 22, 2010 8:21 am Post subject: Re: Best way to cut lexan |
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CUTTING PLEXIGLASS or LEXAN
Tin snips work OK.
Cutoff wheels work but are slow.
A circular saw (for straight cuts) or a bandsaw with a fine tooth blade works well and gets the job done quickly.
Jigsaws sometimes cause trouble on the reverse stroke - not recommended.
Sand all edges smooth when you are done.
Use oversize holes in the plastic for rivets or screws to avoid cracks due to expansion of the plastic.
Use a special drill bit designed to drill plastics or grind standard drill bit lips to completely remove the rake angle so it won’t hog in (grind the lips along the flutes so that the lip face is parallel with the length of the drill bit).
Try to mount (rivets/screws) the plastic slightly on the loose side so it can “give.â€
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Jerry King
Last edited by racerjerry on Fri Jan 22, 2010 8:45 am; edited 1 time in total |
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albertakolbmk3
Joined: 13 Jun 2009
Posts: 69
Location: Innisfail, AB
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| Posted: Fri Jan 22, 2010 8:38 am Post subject: Re: Best way to cut lexan |
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Jerry,
Thanks for the tips.
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_________________
Tony B.
Kolb MKIII C
Rotax 582
C Gearbox 3.00:1
WD 66" 3 Blade Prop |
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