Best way to make a (nice) hole in a lexan body

[ShowRide]

Hi,

I'm working on some kind of special project (I'll certainly post pictures in my showroom when it's finished) and need some help.

In fact I need to make some (oval and square) holes in a lexan body shell. I never did this before and they need to be perfect. What's the best way to do this; exacto knife, scissors, or maybe just make a hole and than make it bigger and correct by using a Dremel?

Anyone any experience or suggestions?

Thanks in advance,

ShowRide

[Shodog]

I use my dremel to do holes. I use the bit made out of rock that looks like a bullet. That way I can make them many diameters

Jim

[WillyChang]

Try a body reamer, they work great. Once you've got one you'll wonder how you ever got along without one. [8D]

[ShowRide]

Hi guys,

thanks for the replies, in fact I use both mentionned methods but for small round holes. My problem now is that I have to make some bigger holes and some of them need to be square (2 cm by 3 cm)... Naturally I need the lines to be perfectly straight. Any suggestions for that?

thanks in advance,

ShowRide

[fury_dice(2)]

quote:

Originally posted by ShowRide

Hi guys,

thanks for the replies, in fact I use both mentionned methods but for small round holes. My problem now is that I have to make some bigger holes and some of them need to be square (2 cm by 3 cm)... Naturally I need the lines to be perfectly straight. Any suggestions for that?

thanks in advance,

ShowRide

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What about a chassis punch - the type that electronics people use to punch neat holes in aluminium? I think 'Q-Max' is the brand name. This might work if the area to be punched is substantially flat...

[ShowRide]

Hi,

the chassis punch could be a solution but than the size has to match the size of the hole I need and that's not the case [8)]. Furthermore I need a solution for whatever size and kind of hole...

kind regards,

ShowRide

[Bibbo]

For the square holes just drill a round one a nd use a small square file to make it the size you want.

You will have to be careful to get it square but it's not too difficult. Probably practice on some scrap lexan first.

[fury_dice(2)]

quote:

Originally posted by ShowRide

Hi,

the chassis punch could be a solution but than the size has to match the size of the hole I need and that's not the case [8)]. Furthermore I need a solution for whatever size and kind of hole...

kind regards,

ShowRide

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id="quote">id="quote">

Fair comment. Would a 'nibbler' (don't know the technical term) be too large? I've used them on sheet metal before to good effect... I'm just thinking that the 'punching, shearing' route might give neater results than the 'drilling, sawing, filing' where lexan is concerned.

But then again, I never was much of a crafts-person... [8)]

[retro]

Personally, id ont think there are any perfect methods. Lots of techniques can work, care and patience is the important bit.

Personally, I would mark out the holes very carefully, then use a vbery sharp knife, cut out the centres a millimetre or so inside the lines, then trim back the edges until they follow the lines exactly. As long as you take your time and dont try to cut off too much in one go, you should be able to cut any shape you want pretty much perfectly.

[spice]

For me I heat up the tip of my ice pick, that seem to work well. It takes a little practice but once you get the hang of it, you will make perfect holes each time.

[]

[ShowRide]

I think I'll try a combination of sharp knife, reamer and dremel... I hope I'll have the patience to do it slowly but perfect.

It'll be probably somewhere next week that I'll test my patience []

[WillyChang]

btw, have you tried the "score & tear" trick?

Score the lexan with a sharp knife, don't have to cut through.

Then start the tear going at an edge or ream a hole along the score

to get the tear going.

Practice on some scrap, you'll soon get the hang of it.

Makes perfect holes in any shape you want, just be very

careful during the scoring part.

[urban warrior]

Hm ... doesn't do a cal.22 long make a nice hole?[}]

Sorry, but I had to post it.[:I]

Regards, Martin

[ShowRide]

Hi Urban Warrior,

the cal.22 isn't a bad idea but I haven't got a weapon license [8)]

At the other hand I'll try the "score & tear" method on some leftovers to see if it is feaseable.

[terry.sc]

quote:

Originally posted by urban warrior

Hm ... doesn't do a cal.22 long make a nice hole?[}

]

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Don't they use polycarbonate for bulletproof glass?

[urban warrior]

quote:

Originally posted by terry.sc

quote:

Originally posted by urban warrior

Hm ... doesn't do a cal.22 long make a nice hole?[}

]

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id="quote">id="quote">

Don't they use polycarbonate for bulletproof glass?

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Well I don't know, but if so they don't use PC alone or its a lot thicker than a r/c-shell I guess. [?]

I can't help myself, but sometimes I'm a little bit pert. [:I]

Martin

[DJTheo]

quote:Don't they use polycarbonate for bulletproof glass?

id="quote">id="quote">

I think they do, but often they use also normal glass with high lead percentage and thickness.