Weir Cut Using Router

[shneerf]

Quick question. I'm creating 1 inch slots in 3/4 inch acrylic. My process is to drill a hole, then use a straight router bit to finish the slot. I haven't done this yet but imagining it I could see there not being enough clearance for the cut material to escape and I might gum it up due to the acrylic not being able to escape. Has anyone tried doing it this way and had success? These slots are closed, as in they do not come out of the flat top part of the tank, like a long pill shape.

 

[redfishbluefish]

I'm not following how you actually want to cut, but let me tell you my experience in cutting 1/2 acrylic.

First off I'd make a template. The reason is that the cutting will require multiple passes. Because you are now using a template, you'll need a collar on the router plate that will follow the template. I don't actually measure, but typically take about 4-5 passes to cut through 1/2". If I cut too much in one pass, the slowness of the cut and heat build-up simply melts the acrylic instead of cutting it.

 

[shneerf]

That helps me a lot thank you. I planned on doing it in one pass so it's a good thing I asked before I turned my acrylic into goo.

I made a pilot hole with a drill but this process is extremely time consuming. I was wondering if it is necessary or is there a better way?

 

[redfishbluefish]

Again, not quite sure what you're specifically doing, but don't understand the need for a pilot hole. The template will guide where the router goes, and if you have a plunging router, you're right on the money for a starting point.

 

[shneerf]

I didn't know routers can drill the hole... The blade looks like it only cuts sideways. Now looking into it they can plunge about 1/8 inch before you have problems. Never saw any videos of routers drilling the hole and only saw them used in a sweeping fashion. So I guess I spent all that that time drilling for nothing haha.

 

[ca1ore]

Two basic kinds of hand held routers - static and plunge. Latter can make the starting hole. Key is multiple passes taking out small amounts of material each time. I always use an upcut spiral bit for acrylic. Helps to remove the waste material and not bind up the bit.

Just be very careful and use safety goggles.

 

[AlexG]

I would agree with making a jig to make the cuts and use multiple passes to take off thin layers of material that does not overwork the material or the router. If you don't have a plunge router then pilot holes are needed but if its a plunge router it will be able to drill the starting and finishing holes.

 

[Lost in the Sauce]

That helps me a lot thank you. I planned on doing it in one pass so it's a good thing I asked before I turned my acrylic into goo.

I made a pilot hole with a drill but this process is extremely time consuming. I was wondering if it is necessary or is there a better way?

That sounds terrible. I would be drilling and end at the stop point, set it up vertical against my sled for the table saw with the blade raised to the height to touch your hole, line it up with your zero clearance insert and make a cut on both sides this will give you a rounded bottom straight sides less mess and no chance of melting.

If you have a band saw, it's even easier.

 

[shneerf]

That sounds terrible. I would be drilling and end at the stop point, set it up vertical against my sled for the table saw with the blade raised to the height to touch your hole, line it up with your zero clearance insert and make a cut on both sides this will give you a rounded bottom straight sides less mess and no chance of melting.

If you have a band saw, it's even easier.

I don't have a sled or table saw. Just a $30 trim router from harbor freight.

 

[Lost in the Sauce]

I don't have a sled or table saw. Just a $30 trim router from harbor freight.

Get free to DM me. I'm happy to draw up something for you to build a SUPER simple router table for lack of a better word with fence. It's More of a shop jig that would need a drill to build , which you already have, and two cuts of plywood that you can buy precut at Home Depot/Menards.

I know it's a stretch but if you're anywhere close to socal, you're welcome to come do it in my shop. Would be a 20-30 minute job including setup and a beer break :cool:

 

[shneerf]

Get free to DM me. I'm happy to draw up something for you to build a SUPER simple router table for lack of a better word with fence. It's More of a shop jig that would need a drill to build , which you already have, and two cuts of plywood that you can buy precut at Home Depot/Menards.

I know it's a stretch but if you're anywhere close to socal, you're welcome to come do it in my shop. Would be a 20-30 minute job including setup and a beer break :cool:

I was thinking of making one but right now I'm in an apartment with very little storage space and it will just add clutter. I live in Raleigh NC so if that's nearby I might take you up on that offer.

 

[neonreef3d]

Quick question. I'm creating 1 inch slots in 3/4 inch acrylic. My process is to drill a hole, then use a straight router bit to finish the slot. I haven't done this yet but imagining it I could see there not being enough clearance for the cut material to escape and I might gum it up due to the acrylic not being able to escape. Has anyone tried doing it this way and had success? These slots are closed, as in they do not come out of the flat top part of the tank, like a long pill shape.

if you were in Los angeles, I would have offered to help, but I see that you are in NC. I have a cnc router that would have done the job in 5 min... :(

Hope you can figure it out, best way is to install your router to a table, and install a guide to help line up the material.

 

[Lost in the Sauce]

if you were in Los angeles, I would have offered to help, but I see that you are in NC. I have a cnc router that would have done the job in 5 min... :(

Hope you can figure it out, best way is to install your router to a table, and install a guide to help line up the material.

Hey Neighbor.

 

[neonreef3d]

Hey Neighbor.

yello

 

[shneerf]

I ended up using the router. Cut through it easily but I had to do it about 1 to 2 mm at a time. This whole thing took me about 2 1/2 hours to do but the end result looks very precise and professional.

 

[neonreef3d]

I ended up using the router. Cut through it easily but I had to do it about 1 to 2 mm at a time. This whole thing took me about 2 1/2 hours to do but the end result looks very precise and professional.

Sounds about right,, cnc would have take. About 10 min or so , maybe less.. for you to do it 2mm at a time was the right thing to do!! Looks good!!

 

[Breadman03]

I ended up using the router. Cut through it easily but I had to do it about 1 to 2 mm at a time. This whole thing took me about 2 1/2 hours to do but the end result looks very precise and professional.

The pros got fast by starting slow. Nice work!