Cutting Plexi or Lexan

[Lance Jones]

I have a sheet of each. What is the preferred method of cutting them?

[waterdog]

Rough cut 1/8" to 1/4" oversize with a jig saw, band saw, or table saw with a good sharp blade.   Cut to final dimension with a flush trim router bit and a bearing that runs around whatever piece you are replacing as a template stuck on with double sided tape.  Hit the edges with a heat gun to make it perfectly smooth (unless you want adhesive on the edge then leave slightly rough).   

[David Urscheler]

A fine toothed plywood blade on a skil saw works great. Tape the edge before cutting just in case.

Dave

[pablosgirl]

I rough cut with a plywood blade or a jigsaw blade leaving a 1/8" and then finish the cut with a belt sander with 150 grit paper and then hit it with the heat gun for the final finish.

Paul

[cmainprize]

flush trim bit and a template works really well.

[Ken Juul]

The key in all these methods is to have a stable platform.  I tried cutting a piece of plexiglass (1/4") with a sabre saw on a picnic table.  Shattered is the polite word.  Another thought is slow....too much heat and the blade melts rather than cutting.  Stable table with a slow feed.  Finish with heat or very fine sand paper.

[Ron Hill]

As Ken said SLOW  is the key with a hand saber saw or best is a band saw.  Also go slow with a router or you'll melt rather than cut the plastic!!

[Lance Jones]

Thanks all!