Plexiglass, Acrylic, Polycarbonate

[ervand]

As I understand all of these three materials look fairly the same (Plexiglass, Acrylic, Polycarbonate)? Except some of them are stronger, some of them are cheaper and so on.. I never done anything with this materials, my questions are:

1. what do I use to cut these materials?
2. after i cut it a sheet it won't look good on the sides. what do i use to make it nice a smooth? (any better solutions then sanding paper?
3. What do I use to cut perfect circles?
4. to cut a sheet with a perfect 90 degree cut what do I use?

Never done any work with computer/case moding. I have a good experience with wood thought. Any suggestions to a beginner?

I actually need names of hardware and tools. My English is bad and I don't know the names of tools. Your tips will help me go the right way when I look for them in a hardware store.


PS: one more offtopic question. I have two computers. I want to get read of a monitor from the oldest one and use it as a server to store files on it. I probably will only need to keep motherboard, memory sticks, processor, hard drive and power block on it? Basecly i just want to make a huge external hard drive out of it =) what else do i need to set it up? what cables, to connect it to my main computer? (never dealed with networking too)

[ervand]

There was 20 views of this page,
No one wants to help me out with these simple questions?

[xRyokenx]

Well dude, it's not that no one wants to help, it's that nobody has an answer... I would've responded earlier, but I decided to wait and see if anyone else did. But yeah, try out the "Search" feature, I think I've seen a thread like this before.

Oh, and welcome to TBCS!

[elbarto241]

1. what do I use to cut these materials?
your choices are: electric jigsaw, bandsaw, or a hacksaw.
2. after i cut it a sheet it won't look good on the sides. what do i use to make it nice a smooth? (any better solutions then sanding paper?
flame polishing or wet-sanding does the trick
3. What do I use to cut perfect circles?
ummm depending on the side of the circle you can just cut out a rough circle, then drill a hole in the middle. mount a bolt on the hole and then throw that on a drill press or a clamped down hand drill. turn on the drill and use a sanding block to bring it down to size and bamn. perfect circle
4. to cut a sheet with a perfect 90 degree cut what do I use?
T-square, and a guiding piece of wood for straight lines.
Never done any work with computer/case moding. I have a good experience with wood thought. Any suggestions to a beginner?
take your time and don't rush through things. hate to see half-asses things that could of been great if a little more time was invested.

the other questions i couldn't really give an informative answer to....

if you still have doubts dont be afraid to ask again

[ervand]

Oh, and welcome to TBCS!
Thanks! I plan to be pretty active! Especially with so many questions =)



if you still have doubts dont be afraid to ask again
I do have a lot of questions regarding your reply. I would greatly appreciate if you help me out with the following questions:

Following questions are based on elbarto241 answers, but anybody's help is appreciated.

1. Electric Jig Saw
After browsing ebay I came up with several questions about it. Before I start I want you know that I never used this tool. So here we go:
1) Most of what i seen in range of $40-$60 are 500-3000 strokes per minute... Is this good anough for cutting straight/organic cuts on wood/metal?
2) There are some that come with laser pointers. Does it help a lot? Or is it just a nice thing to have?
3) There are some that can do 0 / 45 degree cuts. Does work well usually? or it isn't any good? (I am talking from experience after using some tools that had ability to cut 45 degree cuts, but never really worked. Like my phome-board cutter =/ )
4) What are scrolling/orbital jig saws? How are they different? Which one is best for me?
5) From what I understand these two choices are going to fit my needs. But I want to see if you answers are going to change my opinion. Mean while can you take a look at them and tell me which one you like more? I like the first one since it come with a box to store it. I like the second one, since it has a laser. What do you think? link 1 (http://cgi.ebay.com/DeWALT-DW317K-R-Heavy-Duty-Compact-Orbital-Jig-Saw-Kit_W0QQitemZ120155722955QQihZ002QQcategoryZ20786Q QssPageNameZWDVWQQrdZ1QQcmdZViewItem) link 2 (http://cgi.ebay.com/Laser-Jigsaw-Jig-Saw-60MM-w-2-Blades-UL-Power-Tool_W0QQitemZ300147423411QQihZ020QQcategoryZ20786 QQssPageNameZWDVWQQrdZ1QQcmdZViewItem#ebayphotohos ting) (It is ok if it is going to end before you/anybody answers. There are many more actions going on for the same tool and offer)
6) I just noticed that a jig saw on a second link costs much less. Does it mean it is crappy one? It's specifications look like most ~$50 ones, even better...

2. Making cuts look nice and smooth
Flame polishing won't work for me because of conditions I am working in. Wet-sanding - probably too.
1) How do you call a electronic tool that can sand paper/polish stuff?
2) An easier solution could be head that can be pluged into regular hole-driller with sanding-paper on the end? If so how do you call it?

3. Perfect circles
I don't really get it, but from what I get it is not what I am going to use. I am thinking of a same solution just as with sanding-paper with a regular driller.
1) Here it is! I found it! (http://img508.imageshack.us/img508/1572/009jl4.jpg) is that any good? if yes, how do you call those kinds of heads.

Your help is highly appreciated!
Thanks!

[Jim Beam]

1. Electric Jig Saw
After browsing ebay I came up with several questions about it. Before I start I want you know that I never used this tool. So here we go:
1) Most of what i seen in range of $40-$60 are 500-3000 strokes per minute... Is this good anough for cutting straight/organic cuts on wood/metal?
Yes these are good enough you should get a variable speed one because you may want to vary speed depending upon the material
2) There are some that come with laser pointers. Does it help a lot? Or is it just a nice thing to have?
nope its a waste of money because your usually not cutting in a straight line.
3) There are some that can do 0 / 45 degree cuts. Does work well usually? or it isn't any good? (I am talking from experience after using some tools that had ability to cut 45 degree cuts, but never really worked. Like my phome-board cutter =/ )
no it isn't usually great because the blade flexes and tends to wander
4) What are scrolling/orbital jig saws? How are they different? Which one is best for me?
doesn't matter for cutting metals or plexi the material is to hard for you to use the orbital feature if you cut wood it increases the speed which you can cut
5) From what I understand these two choices are going to fit my needs. But I want to see if you answers are going to change my opinion. Mean while can you take a look at them and tell me which one you like more? I like the first one since it come with a box to store it. I like the second one, since it has a laser. What do you think? link 1 link 2 (It is ok if it is going to end before you/anybody answers. There are many more actions going on for the same tool and offer)
if it were me I would get a scroll saw instead it offers better control and tighter cuts than a jig saw
6) I just noticed that a jig saw on a second link costs much less. Does it mean it is crappy one? It's specifications look like most ~$50 ones, even better...

[elbarto241]

4) oribital/scrolling jigsaw are just a feature which lets you turn the blade while your pushing to make a gentle curve. i rarely use it on metal, i use it more on wood.

make sure you get a metal blade for cutting metal and a wood blade for cutting wood. thats an easy way to mess up

5) a scrolls saw is good to make really tight cuts like tribal'soverkill BLACKOUT. if your going to be making large cuts with SOME intricate designs go for the jigsaw.

6) the brand of tool doesnt really matter, everyone has their favorite. just try to get the most powerful one you can afford.

oh and that thing to cut perfect circles is called a hole saw. they can go anywhere from $10-$100 [depending on the size].

[tybrenis]

What size of circles are you talking about? Turning a circle on a drill press is extremely dangerous and shouldn't be done, by the way...

A scroll saw or jig saw is NOT your best bet to cut acrylic with. A table saw is. Even with fine toothed metal blades jigsaws are not great for cutting with when it comes to acrylic, and especially not straight lines.

For the edges you'll want to scrape them, then you can flame polish them. You can ue any type of metal with a nice, crisp 90 degree edge. However, you said you can't flame polish - so scrape the edges down, and start with 400 grit sandpaper and work your way up to 2000 grit, all wet, ie 400, 600, 1000, 1500, 2000. Then you'll want to use some sort of polish to finish it off.

The best way to sand acrylic is probably without power sanders and tools, unless it is a big, wide, flat edge. Small files and sandpaper on a block of wood with help tremendously, remember - its plastic, itd easy to shape.

Finally, there is no difference between plexiglas and acrylic. Plexiglas is a brand name of acrylic, they are both polymethyl methacrylate. Polycarbonate is all together different. People group it to similar to acrylic simply because they are both clear, but it is no where near it - what those people don't know is that almost all plastics start of clear before they are dyed a certain color, ie. PVC, styrenes, etc.

Hope that cleared up some very false information that modders love to spread before they have even tried things themselves...

[elbarto241]

spinning a piece of acrylic isn't dangerous also long as it isn't bigger than 4inches and spins at a low speed. im not at all recommending to attach a 3ft oval to a drill press, crank up the speed and hit the start button.

a jigsaw and a scroll saw are sometimes the better tools than a table saw because of how little they cost compared to a table saw. they also have the ability to curve while their cutting, something i havnt seen a table saw do. in most cases you can buy both a decent jigsaw and scroll saw for half of what a table saw cost.

[.Maleficus.]

A jigsaw is not a good option. Period. Unless you're dealing with 1/4" thick or higher, don't use it. You'll save yourself headaches. At a low speed, the plexi will wobble and crack. At a high speed, the plexi will melt, fuse back together, and/or crack. A Dremel works better. Trust me, this is from experience.

Like ty said (who happens to be the plastic king) a table saw is better. If all else fails, get a Dremel. They can cut plexi for the most part, and do other useful things.

[elbarto241]

i have to kindly disagree. ive cut 2/16" acrylic VERY easily with out any woble or cracking. i just clamped down the piece beneath a large piece of wood every tight against a study work bench and made sure anything didn't vibrate. i have a variable speed jigsaw so when i cut it didnt fuse back together or cracked.

and yes ty is THE plastic king, no doubt about that.

[ervand]

- Regarding a scroll saw
1) I think the strikes per minute is twice less less then on a jigsaw, but I really have a limited money source. So tell me what do guys think about this one (http://cgi.ebay.com/NEW-RAND-16-Scroll-Saw-Jigsaw-Jig-Saw_W0QQitemZ190146373145QQihZ009QQcategoryZ20786Q QssPageNameZWDVWQQrdZ1QQcmdZViewItem)?
2) Is a scroll saw good on curved AND straight line cuts?
3) Is it too loud? =/ I am going to work on a balcony of my apartment. Don't want to bother my neighbors, but if it is the only best option f*ck them =)

- Regarding hole saw
1) I understand that cheaper it is, faster it will brake, but is this good anough for wood/acrilic? link to ebay (http://cgi.ebay.com/ebaymotors/16-PIECE-HOLE-SAW-KIT-NEW_W0QQcmdZViewItemQQcategoryZ26448QQihZ020QQitem Z300146771827QQrdZ1QQsspagenameZWDVW#ebayphotohost ing)
2) Is there anything else I need to attach it to a regular hole driller? Or everything is in the box?

- Regarding table saw
1) I appreciate your replies tybrenis, but a decent one is way too big, expensive, and probably loud too.
2) I don't think it will cut curved lines too, and I do have some ideas for tribal designs (not too complicated ones, but still)

- Regarding sanding/polishing
1) can some one explain me how do I wet sanding?? I only did it dry =)
2) what do i use to polish? how do you call that tool

- Regarding jig saws with lasers
1) It is not useful on curved lines, but what about straight lines? Does it help on straight lines?
2) I do plan to use something thicker then 1/4" acrilic sheet. Jigsaw will do?

- Based on all the facts i think jigsaw will do best for me. Especially if i use it like elbarto241 (keep in mind that I am going to use sheets of acrylic thinker then 1/4".

I think this is turning out a good topic for beginners that want to work with wood/acrilic (like me) =)

[elbarto241]

regarding that holesaw on ebay, looks like everything you need is on that kit [good price too].

wetsanding is just the way it sounds. submerge your wetsanding paper in water and wet the piece of material you are going to sand. just make sure you have WETsanding paper, not the regular kind.

about flame polishing most people use a small butane torch. THIS (http://www.thebestcasescenario.com/forum/showthread.php?t=2960)should help

and you shouldnt have any trouble cutting think acrylic as long as you use proper clamping and a right blade.

[.Maleficus.]

Wetsanding is easier with a few drops of dish soap. Makes it glide nice.

A scroll saw will cut curved lines. Probably better than anything else you'd be using. That's exactly why I'm looking into one. I need some good curves.

[ervand]

Remaining questions:

- Regarding a scroll saw
1) Is it too loud? =/ I am going to work on a balcony of my apartment. Don't want to bother my neighbors, but if it is the only best option f*ck them =)

- Regarding hole saw
1) I understand that cheaper it is, faster it will brake, but is this good anough for wood/acrilic? link to ebay (http://cgi.ebay.com/ebaymotors/16-PIECE-HOLE-SAW-KIT-NEW_W0QQcmdZViewItemQQcategoryZ26448QQihZ020QQitem Z300146771827QQrdZ1QQsspagenameZWDVW#ebayphotohost ing)
2) Is there anything else I need to attach it to a regular hole driller? Or everything is in the box?

- Regarding table saw
1) I appreciate your replies tybrenis, but a decent one is way too big, expensive, and probably loud too.
2) I don't think it will cut curved lines too, and I do have some ideas for tribal designs (not too complicated ones, but still)

- Regarding sanding/polishing
1) can some one explain me how do I wet sanding?? I only did it dry =)
2) what do i use to polish? how do you call that tool

- Regarding jig saws with lasers
1) It is not useful on curved lines, but what about straight lines? Does it help on straight lines?
2) I do plan to use something thicker then 1/4" acrilic sheet. Jigsaw will do?

Thanks guys! you are really helping me!

[crazybillybob]

Welcome to TBCS.

This statement is for both Jigsaws and scroll saws. VARIABLE SPEED! If your going to spend the money for a tool spend the extra and get the variable speed model, they allow the tool to be so much more flexible (you can use for metals, thicker stock plastics and woods, and get better surface finish.) This makes your money go farther. A scroll saw can be a bit loud, normally it's not the saw it's the saw vibrating on the work bench or table... to cut down on that glue down some old thick mouse pads to the bench then put the saw on top of it.

I've used a jig saw to cut all kinds of stuff that people have told me can't be cut or can't be cut well with a jig saw... With plex I've cut 1/8 and thinner with no problem. I'll take a jig saw over a dremel any day of the week for plex. Now when you get up to 3/4" + the on;y way to cut it is a table saw! anything else it just welds it's self back together. Now for fine details, and tight turns you can't beat a scroll saw. Straight lines are tough with both a Jig saw and a scroll saw , the blades are very thin and very narrow, there made for turns and such. I'm not sure a laser would be that much help..but I've never had a fancy jig saw with one.

The hole saws you've shown, will cut round holes (got a set myself..you can get them from Harbor freight for $2.99 on sale) but there will be a hole in the middle from the pilot drill, and the hole isn't always perfectly round, and they like to wonder allot.

wet sanding is done just like dry, you just need water (a couple drops of dish soap) and wet sanding sand paper (has a cloth back and the sand is glued on with glue that doesn't dissolve in water). I just put a couple inches of water in a tub big enough for what I'm working on (kitchen sink works too), get the item and the paper wet the start sanding, just remember to keep wetting the paper (it washes the grim out the the paper and lets you sand with fine paper longer..and keep a smooth finish).
Polishing you don't need a tool just some plastic polish and a cloth....and some elbow grease. Then buff it out.

Good Luck,
CrazyBillyBob

[ervand]

Thank you very much!
If any one got anything else to say or give a few useful hints I would always appreciate it!

Once again, thank crazybillybob!

Edit:
I would give you one more +rep just for that -> Harbor Freight, but I can't since forum system does not allow more then one rep per person.


One more question!
- Is there anything that a jigsaw can do that scroll saw can't?!

My father thinks it does, but he is not sure. So he is thinking about getting both =)
and it is very possible even thought I don't want to spend too much on this. check it out.

it is the same jigsaw i seen on ebay
http://www.harborfreight.com/cpi/ctaf/Displayitem.taf?itemnumber=92772

and twice better scroll saw since it has variable speeds and 0 to 45 degree cut
http://www.harborfreight.com/cpi/ctaf/displayitem.taf?Itemnumber=93012

I think it is a great price and tools are treaty deacent.

I just need to know what a jig saw can do that a scroll saw can't

thanks

[ervand]

nothing is here, sorry. =)

[crazybillybob]

Biggest plus for the jigsaw... It's portable, and if you know how to use it you can start cutting without pre-drilling a pilot hole (normally only done in wood).
With a good quality blade (I'm going to toot Bosh's horn again..They cost more but they are worth every penny, they last longer, cut cleaner and give you better control!) You can use a Jig saw to cut Steel, and thicker aluminum. Scroll saw can cut 1/8" aluminum well but the blades are so small and thin that they over heat and break when cutting steel or overly thick aluminum. Jig saws do a bang up job on cutting paneling (like cutouts for outlets and gang boxes, etc.)

Is that good enough??
Glad I could help you out. ;)

CrazyBillyBob

[ervand]

yeah you did big time,
all the other stuff that I was planing to buy (just didn't talk about it here) is there for a smaller price, so I am buying everything i planed to and even more ;)

Since I am spending less then I thought I would and the jigsaw is only $20 - I think I will find some use for it =)

Thanks again.

[ervand]

I already bought all those tools, they were delivered and I am very satisfied with them!
But now I am looking for a table saw and I have few very quick questions:

1. when I was looking for a table saw I seen 4" to 10" table saws and I got confused. Does that mean it is (for example) 4" for maximum cutting depth? or it is 4" diameter blade that this table saw can fit?

2. if it is just the blade diameter - I can get one that says 4" and cut 24"x24" acrylic sheet in two pieces (so that the cutting depth was 12"x24") easily? Am I right?

3. I have a choice between this three saws:
- http://cgi.ebay.com/RYOBI-10-PORTABLE-TABLE-SAW-with-STAND-1-YR-WARRANTY_W0QQitemZ260165714186QQihZ016QQcategoryZ2 0789QQssPageNameZWDVWQQrdZ1QQcmdZViewItem
- http://www.harborfreight.com/cpi/ctaf/displayitem.taf?Itemnumber=45804
- http://www.harborfreight.com/cpi/ctaf/displayitem.taf?Itemnumber=93211

Can you help me with my choice? Don't consider the price, because it compensates and comes up to about the same price, because some of those don't have table stands and some do.

4. Are these blades good enough for acrylic and general purposes like wood?
http://www.harborfreight.com/cpi/ctaf/displayitem.taf?Itemnumber=38133

After i make this purchase I will buy acrylic and start working on my project.

[crazybillybob]

The 10" and 4" are the diameter of the blades The material thickness they can cut max is listed for each saw, about 2 7/8" for the 10" and 3/4" for the 4" . So if you want a good general purpose saw (for use after this project) I'd get the 10" saw. I'd also go with the Ryobi over the Harbor freight ones. Harbor freight are low cost but you get what you pay for... spend the extra on a table saw! As for the blades, you'll need to find some 10" ones to go with the saw (harbor freight doesn't carry that 5 pack in 10"). For plex you want a high tooth count blade (120-180 Tooth) (also called plywood blades), they make a smoother cut but can only be used on thinner material (3/4" or less) a 60 or 80 tooth blade is good for 2x4's and the like... but not great for plex.

Hope that gets you on the right path!
CrazyBillyBob

[ervand]

I found out that those cheap ones have a problem with a blade. all of them. it is a little off. that what all reviewers say. very few people were satisfied. i found out this one is the cheapest that you can get with out that problem + it got lots of nice features that other table saws offer for this price.

http://www.amazon.com/JET-708315BTC-JBTS-10BT-3-Benchtop-Table/dp/B000CFH3A8/ref=pd_bbs_sr_3/002-0601365-6461607?ie=UTF8&s=hi&qid=1191395603&sr=8-3

[Slaughter]

Hi guys,

I am reading those forums for a while :D, ervand I have to say that I never had problems with my dremel scroll saw (it is just great) I believe it worth every penny! As for a table saw to big for detail work and no need for modding especially when you work with plexiglass, aluminum, steel and other stuff that a scroll saw can easily handle! Also, you can go with a cheaper one if you don't have the budget on the dremel one!

This is my experience over the years! But I am sure Billy will find a way to shut my moth :p

[ervand]

I did get a scroll saw and I use it a lot since a first day when I got it! I have to take a lot of Architecture classes in my college because my goal is Architecture. We always have to make models and so on, so I do need both of them. It is kind of hard to make straight lines with a scroll saw, that's why I need a table saw. Especial for the 45 degree cuts with I do a lot. I can make it with a scroll saw, but it is too challenging I could never get a PERFECT, CRISP corners when I am done with my model.

I just bought that table saw that I linked above and waiting for it to deliver. I also bough a 10" plywood blade with (180 teeth).

Waiting for it to deliver.

[ervand]

A table saw got delivered, gonna look for some acrylic now.
I know some people linked me to some of their favorite websites above and I am going to look over them right now, but I would appreciate if I got more sources too look at!

So if someone got anything nice to share I wold be more then happy to! I am looking for:
+ acrylic
+ bulbs and lighting of all kinds of sorts.
+ anything else out there that can make my case look good. any nice website. even if it only sells screws!

[rendermandan]

here you go.
http://www.thebestcasescenario.com/forum/showthread.php?t=8546

[crazybillybob]

Hi guys,

I am reading those forums for a while :D, ervand I have to say that I never had problems with my dremel scroll saw (it is just great) I believe it worth every penny! As for a table saw to big for detail work and no need for modding especially when you work with plexiglass, aluminum, steel and other stuff that a scroll saw can easily handle! Also, you can go with a cheaper one if you don't have the budget on the dremel one!

This is my experience over the years! But I am sure Billy will find a way to shut my moth :p


Slaughter,
What do you mean the table saw is to big for detail work? Your just not building a big enough mod then :)... The table saws are large but, you can't beat them for crisp straight lines and beveled cuts. Plus it's good for ripping down sheets of material for use on the scroll saw (as plex, sintra, and wood are cheaper in the 4'x8' sizes). Plus you just can't do a rabbit (a type of joint where you cut a slot into one piece that's just the thickness of the piece that fits into it)with the scroll saw :) ...Both are wonderfully tools to own, especially if you do other kinds of work or home improvements as well as modding!

CrazyBillyBob

[ervand]

A nice guide on how to use a table saw would be nice.

I know it might sound stupid, but I didn't expect it to be that hard to make 1.5" squares beveled 45 degrees from every side in order to make a perfect 1.5" cube. I didn't make it, but I tried MY way, which I don't think is the way it goes. Thus I had little offs here and there and didn't come up with a perfect cube with nice, crisp edges.

I was working on a plywood with a plywood blade (180 teeth)

Maybe some one more experienced could suggest me anything?!

PS: I am also afraid of this thing now =) You do one wrong move and wooalah! no more fingers =)

[ervand]

up

[Kill_Switch]

There is a little tool you can cut out with a jigsaw or scroll saw that allows yout o pass the wood through the table without the fear of cutting your fingers off. It looks like a simple handle with a 1/2 inch (your choice) knotch at the bottom to grab the workpiece and help guide it through.

But never keeping you mind of the focus of the job at hand or you may cause an accident.

Here is one you can purchase, LINK (http://www.woodsmithstore.com/433101p.html)

or you can make one out of scrap material lying around.
http://www.thenewchinkyworkshop.com/PushNSandingBlock.JPG

[ervand]

http://www.harborfreight.com/cpi/ctaf/displayitem.taf?Itemnumber=92194

1. Is this thing with the wheel that it comes with any good for polishing acrylic?
2. Is polishing the same thing as buffing?

[ervand]

up

[tybrenis]

No. Don't buy a buffer for acrylic - its useless. You'll have to do that by hand using a dust-free/lintless rag. Buffing it will just give you problems.