Re: Working with Plexiglas

["Tesla list" <tesla-at-pupman-dot-com>]

Original poster: "Michael O. Poley by way of Terry Fritz <twftesla-at-qwest-dot-net>" <mpoley-at-mindspring-dot-com>

At 09:21 PM 6/26/01 -0600, Tesla list wrote:
>Original poster: "Gregory Hunter by way of Terry Fritz 
><twftesla-at-qwest-dot-net>" <ghunter31014-at-yahoo-dot-com>
>
>Dear List,
>
>I sometimes use Plexiglas for Tesla coil components,
>but I still haven't figured out how to work the stuff.
>  When I saw it with an electric jigsaw, the cut tends
>to fuse back together after the blade has passed.
>When I finally do get the stuff cut, I have a rough
>edge that defies my best efforts to smooth & polish
>it.  What's the secret to cutting Plexiglas sheet?
>How do I get a professional-looking finish on the
>edges?  What's the best glue to use with it?  How do I
>use power tools on it without melting it?

Oh, oh, I can help!  Fancy that.

I had the same problem.  I asked the guy at the hardware warehouse, and he 
told me that _any_ power tool is going to create enough friction to (1) 
melt the "Plexiglass dust" and create a rough edge, and (2) gum up any 
power tool you might be using.  He said he'd used a table saw to cut some 
plastic for a display, and he regretted doing it (and he's a professional!)

His advice:  Go to the flooring department of the hardware store, and get a 
"scoring tool".  It's just a handle on one end and tungsten carbide scoring 
tips on the other end.  Mine has two curving around, looking a little like 
horns.  Lay your straightedge along the Plexiglass and, using pressure, 
make a deep scratch along the straightedge.  Do this a few times, being 
careful to go right along the old scratch (fiducial reference line, for 
those of you writing research papers).

All this will do is give the Plexiglass a place to break.  Next, lay the 
sheet of Plexiglass on a 2"x4" or some other board, with the scratch along 
the edge of the board, facing up.  Now, just snap it by pressing down.  You 
could turn all this upside-down and snap it by pulling up.

Good luck.  Safety first!


Michael O. Poley
mpoley-at-mindspring-dot-com