cutting lucite with hole saw
 

Hi all!
ummm.. the topic basically explains it all. I read in another post that melting plexi can release cancerous vapors, but what about using a hole saw to cut the plexi? Any bad fumes or side effects I should know about before I try it out?

Thanks!

From what I understand about the thread you are talking about.....as long as you dont allow the plexi to heat up to the point of burning, you should be fine.

Just cut the lexan in a bucket, or pour water on the lexan and you'll be fine.

doesn't water + power drill = bad?

Yes... .but small amounts of water poured on hole saw keeps it cool, which is good.

So long as you don't get water on the drill, you should be fine...

Basically, you'll just burn the plastic if you use a hole saw, with nothing to cool it. Hell, I've set MDF on fire using a 5" diameter hole saw with a Dewalt Industrial grade 120vAC drill. :D But seriously... just something to cool it... hell, you could just hold an ice cube up to the hole saw as you drill, that should be sufficient.

If I drilled in a bucket of water, then should the plexi be submerged a little (~2mm under the water line)?

Thanks for the replies!

That'll be fine.

Just cut it in a well ventilated area i.e. outside. I've been praticing enough with lucite since I'm making a case out of it to know its not bad stuff and is actually easier to work with than I thought. I have no problems drilling, bending(via a heatgun), or cutting it on a table saw. Just go slow and easy with the stuff and it will reward ya for it.

so i guess i shouldn't go full blast with the power drill huh. Short spurts of drilling (5-10 sec drill, 5-10 sec rest, etc) seem okay? or is longer continous drilling prefered?

Thanks!

You want to be very careful when cutting plexi with a hole saw, first make sure you mask the area where the hole is to be drilled, both front and back, this will add a little strength to it. I clamped my window to a flat board and used a variable speed drill with an 80mm holesaw. You want to keep the holesaw spinning at a fair clip but not so fast that it melts the plexi, the problems arise when you go too fast and then slow way down causing the blade to lock up (melting and then cooling plastic). Do not rock the holesaw if it gets stuck, try reversing the drill to free it up. It is easy to remove any melted plexi from the edge of the hole if you do go too fast, it just snaps right off. Water would keep the plexi from melting as stated above.