Cutting acrylic

smcquary · Aug 14, 2017

Bought a new hob skimmer that doesn't fit into the opening of my acrylic tank and need recommendations on removing a 2" x 1/2" notch.

85173 · Aug 14, 2017

If you get a woodwork router you can set up guides to create your slot that way. If you need to contain the acrylic shavings from entering your system, you could set up a container under the area to catch them.

ReeferBob · Aug 14, 2017

Just use a hacksaw.

Big G · Aug 14, 2017

Dremmel tool works great cutting acrylic. Just go nice and slow, making sure not to "bind" the blade. The sanding attachments also work great on acrylic. Just be care not to "burn" the acrylic. A light touch with brief breaks to let it cool is the hot setup (no pun intended). Keep your hands, fingers clear of the blade. Sometimes it will catch and jump in the direction of blade rotation. Wear eye protection. Getting hot chips of plastic in your eye hurts!

smcquary · Aug 14, 2017

What type of bit would you use in the router? Thanks

Big G · Aug 14, 2017

smcquary said:
What type of bit would you use in the router? Thanks

I would use a router bit that is made for trimming formica or similar materials. Something like this one: https://amazon.com/uxcell-2-Flute-T...8-8&keywords=router+bit+for+trimming+laminate

ReeferBob · Aug 15, 2017

Big G said:
I would use a router bit that is made for trimming formica or similar materials. Something like this one: https://amazon.com/uxcell-2-Flute-T...8-8&keywords=router+bit+for+trimming+laminate

How is that going to work? It isn't for cutting slots it has a bearing that rides on a solid surface.

Big G · Aug 15, 2017

ReeferBob said:
How is that going to work? It isn't for cutting slots it has a bearing that rides on a solid surface.

The OP says he wants a 1/2" slot. That's about what one of these bits takes out when pushed into work material by setting it to cut deeper instead of when just flush trimming the edge off. Just use a clamped straightedge, like a ruler, etc. to guide the cut with against the router baseplate.

ReeferBob · Aug 15, 2017

Big G said:
The OP says he wants a 1/2" slot. That's about what one of these bits takes out when pushed into work material by setting it to cut deeper instead of when just flush trimming the edge off. Just use a clamped straightedge, like a ruler, etc. to guide the cut with against the router baseplate.

hmm... I think your idea has 5 o'clock news written all over it. I would not suggest doing this. I think the hacksaw is the best bet. Also are you aware of how easily acrylic scratches? If he does clamp a guide to let him use a flush bit designed for counter-top Formica trimming to the acrylic, he will get scratches from the clamps as well as the router as it slides along the acrylic. I don't think any router bit is the correct tool for this job.

Big G · Aug 15, 2017

Hey it's just a suggestion. I've done this many times working with acrylic over the decades. Old as dirt. LOL

|FATHOM| · Aug 15, 2017

I've used a drywall router with great success. I just tape over what I am going to cut

Big G · Aug 15, 2017

|FATHOM| said:
I've used a drywall router with great success. I just tape over what I am going to cut

Yep! Been there done that. The small profile makes it handy to use. Only thing is that they have less torque than the larger HP units. So new, sharp carbide blades are the way to go on acrylic.

Acro maniac · Aug 16, 2017

ReeferBob said:
hmm... I think your idea has 5 o'clock news written all over it. I would not suggest doing this. I think the hacksaw is the best bet. Also are you aware of how easily acrylic scratches? If he does clamp a guide to let him use a flush bit designed for counter-top Formica trimming to the acrylic, he will get scratches from the clamps as well as the router as it slides along the acrylic. I don't think any router bit is the correct tool for this job.

Just run a few pieces of 2in painters tape everywhere contact is made and pull it off when your done. I used a router and mica bit for every cut making my sump