Woodworking Talk banner
Cancel

How to cut Lexan?

2681 Views 9 Replies 9 Participants Last post by  27207, 
S
How do you cut Lexan for windows?

I bought 2 pieces of lexan to replace the broken/missing windows in my garage/shop. I need a little help in cutting them to size.

Thanks in advance.
Reply
Save
Like
1 - 10 of 10 Posts
Dave Paine
This will cut easily, but it will be messy.

I would leave on the protective backing to avoid scratches until after cutting/sanding.

Options I would consider in this order :
a) Jig saw.
b) Circ saw. Thinner blade helps.
c) Table saw. Likely blade is not intended for this material. I would actually use the blade at full height to minimize the heat build up. Not the normal approach for such thin material, but this is "special". ;)

All of these will do the cut. I would plan on sanding the edges afterwards.

The circ saw or table saw blade may partially melt the material so the edges may be rough.

This makes a lot of dust and chips. I would clean up between cuts.
See less See more
Reply
Save
Like
F
With a negative hook blade you'll get a lot smoother cut on the table saw (but no less mess).
Reply
Save
Like
cabinetman
If the Lexan is ⅛" you can score a line, hang over the edge of the bench, and snap it down.





.
See less See more
2
Reply
Save
Like
S
Thanks for the quick replies everyone!
Reply
Save
Like
JohnK007
I used my bandsaw when I cut mine. I used it to replace a garage window too. It cut easily enough but was a bit messy. Score and snap like C-man suggests would be fast and less mess if the material is thin enough.
Reply
Save
Like
nostrildamus
I use a table saw but replace the blade with a 40-tooth crosscut blade from my miter saw. I found better results than with a negative-hook "floor-cutting" blade.
Also, wear a respirator when sawing, the fumes can be pretty noxious.
Reply
Save
Like
G
Cutting Lexan

I also use my Band saw. I tape a piece of 1/4" ply to the deck right up against the blade to prevent the melted edge from sticking in the blade insert and watch the speed that I cut. Depending on the thickness of the lexan you may be able to cut it a little faster than you would think. Even though I have a decent dust collection systen on my saw I also vacuum out the inside of the case afer cutting because the plastic seems to form a static cling to anything it can.

Gene
Reply
Save
Like
chicago
Stodg73 said:
How do you cut Lexan for windows?

I bought 2 pieces of lexan to replace the broken/missing windows in my garage/shop. I need a little help in cutting them to size.

Thanks in advance.
Click to expand...
I use my router to cut all of my Lexan.
Reply
Save
Like
2
nostrildamus said:
Also, wear a respirator when sawing, the fumes can be pretty noxious.
Click to expand...
YES! I cut a piece with a router bit in my dremel, it seemed to burn the lexan rather then cut it. I didn't have a mask on, and the fumes burned my nostrils. They didn't fully heal for a month! WEAR A MASK!

I don't believe its such a big deal when using a jigsaw, but I will always wear my mask from now on. Lesson learned!

I also have tried it on my table saw, but my blade was dull and didn't have a lot of teeth, i'm unsure how many it has. Anyways the 1/4" lexan shattered, almost caused a catastrophe, my hand was numb for a couple days, but nothing was bruised or bleeding. I was lucky. Just have a sharp blade with more teeth.
Reply
Save
Like
1 - 10 of 10 Posts
This is an older thread, you may not receive a response, and could be reviving an old thread. Please consider creating a new thread.
Woodworking Talk
A forum community dedicated to professional woodworkers and enthusiasts. Come join the discussion about shop safety, wood, carpentry, lumber, finishing, tools, machinery, woodworking related topics, styles, scales, reviews, accessories, classifieds, and more!
Full Forum Listing
Explore Our Forums
General Woodworking Discussion Power Tools & Machinery Project Showcase Wood Finishing Woodturning
Top