- 1). Leave the protective backing on the plastic to avoid scratching. Size the plastic for cutting using a tape measure. Because cutting leaves a rough edge and must be sanded, the plastic must be over-sized by 1/16-inch in length and width. Use a grease pencil to mark the desired length and width.
- 2). Ensure a square cut and avoid melting the plastic by cutting it with a table saw. Push the plastic into the saw blade at a rate of 10 to 20 feet per minute, using the saw’s fence to guide the material through.
- 3). Remove saw marks created during the cutting process, using a table router. Set the router’s fence so the router will remove 1/32-inch of material on each side of the rough-cut plastic. Push the saw-cut edge along the router’s fence. Route each of the four rough sides once.
- 4
Use a grease pencil to lay out any cutouts.Martin Poole/Digital Vision/Getty Images
Mark any holes or cutouts for drilling on the material once the plastic has been routed. Use a grease pencil, which can easily be wiped off. Make sure cutouts and holes are marked with a clean line. - 5
A drill press is the best tool for hole cutting.Photos.com/Photos.com/Getty Images
Choose drill bits designed for plastic. Acrylic has a tendency to crack under pressure, especially when drilling through it. The correct drill bit will have a long sharp point. Set the drill at a medium speed. Place the point of the bit on the plastic. Gently push down on the drill, releasing the pressure as soon as the drill bit bites into the plastic. - 6). Machine a clean cutout by using a router. Use scrap plastic or lumber to create a routing guide. Use a flush-trim router bit to create the cutout. The bit’s bearing will ride along the guide, creating a smooth edge. Set the table router bit's height so the bearing’s entire side is even with the guide. Set the router’s speed to 22,000 rpm.
- 7). Sand the routed edges of the plastic, using an electric palm sander and 220-grit sandpaper. Allow the sander’s weight to apply the necessary pressure, rather than pushing down on it.
- 8). Cut a beveled edge using a sharp utility knife. Hold the blade at a 45 degree angle to the edge being scraped. In a single long pass, pull the blade along the edge of the plastic.
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