routing 0.08 acrylic - Router Forums
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post #1 of 16 (permalink) Old 12-31-2011, 07:21 PM Thread Starter
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Default routing 0.08 acrylic

I have a piece of 0.08 acrylic 6"x10". I am wanting to cut a 1/2" in from the side and 8" long from the 10" long side leaving an inch long leg on each end of the 8" cut.

Has anyone made a male template and routed with a flush trim bit to take off the acrylic over hang? .... or do you think it possible for it to work with out cracking the acrylic?

I don't have a band saw and am trying to avoid sandwiching the acrylic in between hard board 10 seperate times and using the jig saw to cut it. Thanks.

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post #2 of 16 (permalink) Old 12-31-2011, 08:02 PM
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Clamp it over a table edge & route it off. Use a piece of straight scrap. Make sure table top has straight edge for bearing to ride against. You can pinch it with clamps between the table & the scrap piece. Don't use the dining table you will get in trouble.

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post #3 of 16 (permalink) Old 12-31-2011, 08:19 PM
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That's pretty thin stuff. I think I'd be inclined to use a hacksaw for the 1/2" cuts. Install blade backwards and use pull cuts only. box cutter (razor/stanley/etc) knife to score the 10" cut. 3or 4 scores should put you pretty well through it. That will also give you square corners.

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post #4 of 16 (permalink) Old 12-31-2011, 09:34 PM
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I would not use a router to cut this unless it was sandwiched between two 6"x10" pieces of wood.

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post #5 of 16 (permalink) Old 01-01-2012, 12:02 PM
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Quote:
Originally Posted by RJM60 View Post
I would not use a router to cut this unless it was sandwiched between two 6"x10" pieces of wood.
My solution exactly. I usually sandwich all of my acrylics between 1/4" material when routing it and a bit made especially for acrylic.

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post #6 of 16 (permalink) Old 01-01-2012, 04:43 PM
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Could you cut the ½" cuts with a pair of metal shears, and then score the long cut with a utility knife?

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post #7 of 16 (permalink) Old 01-01-2012, 06:24 PM Thread Starter
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I delayed cutting the acrylic today for all ideas to post in and did some assembling and finishing while I waited.

In the recent past I did try 2 of the suggestions, at the time I had only 2 pieces to cut so used the utility knife. It worked fine but suprisingly took a lot of effort and time to cut through such a thin piece. With 10 pieces to cut I am trying to avoid the utility knife. Also I had tried the metal shears that I use for cutting vinyl and yet again was surprised. The acrylic cracked with every cut!

I don't have an "Acrylic" bit but will try a few suggestions with out it, hand held with a straight edge and a flush/trim bit...... sandwich it in between 2 male templates on the router table...... jig saw with it sandwiched in bewteen 2 hardboards.... hacksaw and utility knife............. looking for the quickest way that works.

Looks like I'll need to order an Acrylic bit before the next time I use Acrylic...

Thanks for your input and I'll post what worked first.

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Last edited by Marco; 01-01-2012 at 06:26 PM.
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post #8 of 16 (permalink) Old 01-07-2012, 01:12 AM
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Quote:
Originally Posted by Ken Bee View Post
bit made especially for acrylic.
Hi Ken,

Do you have any links to such bits?
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post #9 of 16 (permalink) Old 01-07-2012, 07:14 PM Thread Starter
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Default Acrylic notches are cut

Well since several took the time to reply I thought I would post as to how the now 3/4" notches 7" long cuts in ten pieces of acrylic that are 9"x 5 1/4" were done and how they came out.

I cut the 10 pieces of 0.08 acrylic to size 9" x 5 1/4" and then started to try on a piece of scrap cutting with a hacksaw the 3/4" in line. It didn't want to start and seemed like it would be a hassle. So I thought that I could make the 3/4" cut for the notch by standing the piece up and running it through the blade and pressed against the arm of the table saw. It worked and was not unsafe for me so flipped and cut the notch for the other leg. I repeated that and did that nine more times until I had 10 pieces.

I originaly thought that I would be sandwiching the acrylic between hardboard and cutting it with a jig saw or sandwiching it between 2 male templates and using a flush trim bit on the router table after first trying to trim it out with a router using a straight edge but since I had the table saw out.......

After cutting the 3/4" notches I figured I would use a utility knive and score the 7" long cut until it was able to be snapped off. I thought well what if I make a quick zero clearance piece out of luan and raise the table saw blade up while holding the acrylic in place against the table saw fence I would just have to make a small cut with the knife to get the corners. I did that and snuck up to each corner so not to over cut. Flipped it over and snuck up on it again. Half the time it would cut the corner and the other times you could just snap it clean with your fingers.
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post #10 of 16 (permalink) Old 01-07-2012, 07:50 PM
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Hi Jim

Try this little trick, don't cut it off just score it with the table saw on both sides ,it will snap right off clean just like cutting glass..the error comes from the heat of the blade..or router bit..use a Sharp knife to cut the sq.corners..or to say the right angles to the saw cut..


hope this helps



===

Quote:
Originally Posted by Marco View Post
Well since several took the time to reply I thought I would post as to how the now 3/4" notches 7" long cuts in ten pieces of acrylic that are 9"x 5 1/4" were done and how they came out.

I cut the 10 pieces of 0.08 acrylic to size 9" x 5 1/4" and then started to try on a piece of scrap cutting with a hacksaw the 3/4" in line. It didn't want to start and seemed like it would be a hassle. So I thought that I could make the 3/4" cut for the notch by standing the piece up and running it through the blade and pressed against the arm of the table saw. It worked and was not unsafe for me so flipped and cut the notch for the other leg. I repeated that and did that nine more times until I had 10 pieces.

I originaly thought that I would be sandwiching the acrylic between hardboard and cutting it with a jig saw or sandwiching it between 2 male templates and using a flush trim bit on the router table after first trying to trim it out with a router using a straight edge but since I had the table saw out.......

After cutting the 3/4" notches I figured I would use a utility knive and score the 7" long cut until it was able to be snapped off. I thought well what if I make a quick zero clearance piece out of luan and raise the table saw blade up while holding the acrylic in place against the table saw fence I would just have to make a small cut with the knife to get the corners. I did that and snuck up to each corner so not to over cut. Flipped it over and snuck up on it again. Half the time it would cut the corner and the other times you could just snap it clean with your fingers.



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