Best Tool to Cut Lexan Polycarbonate?

Discussion in 'Die-hard Overclocking & Case Modifications' started by Hav0q, Oct 1, 2010.

  1. Hav0q

    Hav0q Master Guru

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    I just purchased a 18x24 sheet of .093 thick Lexan Polycarbonate to replace my Obsidian 800D's stock clear panel. I need to cut it to fit my 200MM fan. Best tool to do so? Maybe use a sharp ass exacto knife and make multiple passes against a straight edge? I just am going to cut a square, so it shouldn't be too difficult. I don't have a dremel but I'll get one if it's better.
     
  2. 3x3cUt0r

    3x3cUt0r Master Guru

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    Get a laser :D
     
  3. dmak

    dmak Master Guru

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    if its just straight lines use a scoring tool, they look like olfa razer knives, but have a hooked tip. If curves, tape + jig saw. Anything complicated... laser (pew pew)
     
  4. PhatKat

    PhatKat Banned

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    Scribe your line, score id to about 1/3 depth, then snap. Trust me, snap. It's unnerving, but works. Any rough edges can be cleaned with a quick shot from a torch, like a butane torch.

    Thicker lexan, I use a jigsaw, and for fan holes, a hole saw.
     

  5. Hav0q

    Hav0q Master Guru

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    Awesome, thanks.
     
  6. PhatKat

    PhatKat Banned

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    No problem. I have plans drawn to make a larger and better case than the one I have, and have a good bit of experience with plastics.
     
  7. Hav0q

    Hav0q Master Guru

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    What kind of hole saw should I use? Or is that just a type of a bit? Ideally I was thinking of putting a 200MM fan on the window but I'm thinking of a 120 or 140 now since airflow is good enough as it is and I already have a good filter/grille kit for a 120 or 140.
     
  8. PhatKat

    PhatKat Banned

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    For 80mm fans, I use a 3" hole saw.

    [​IMG]


    For bigger holes, like you say a 200mm, I would draw the hole with a marker, drill a pilot hole, then cut the hole with a jig saw. You can clean up the hole with a sand drum or a file, then use the torch trick. Also, be sure to leave the outer layer film on the lexan til you are ready to mount it, or use tape to protect it temporarily.

    With a saw in plastic, be careful to not go too fast, you'll melt the plastic, same with a sander.
     
  9. Svein_Skogen

    Svein_Skogen Maha Guru

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    Dremel 678-01 and a 9901 bit.

    //Svein
     
  10. PhatKat

    PhatKat Banned

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    I need to get one, been thinkin about it.
     

  11. Svein_Skogen

    Svein_Skogen Maha Guru

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    That same combo, on a 4000 machine has ... no issues cutting the steel side panels either, btw. Remember to protect your ears, as the sound is horrible...

    //svein
     
  12. Mega_Death

    Mega_Death Maha Guru

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    Go slow with blade speed. High rpm's can melt the edge.

    And not just any laser, you need a CO2.
     
  13. Pablo

    Pablo Ancient Guru

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    Wonder how well it would cut on a bansaw, shame you too far away, could of given it a go for ya.

    Phat, building a new case, nice, post a log dont forget.

    and Svein, talking about cutting noises, when i was drilling through ss316 , taking about 50 mins to drill through, with constant high pitch, can seriously be unbearable.
    (i used to gundril by the way)
     
  14. Hav0q

    Hav0q Master Guru

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    Yep, tuesday I'll have pics up because that's my next day off. Hopefully all goes well. Just can't decide between a 120, 140, 200 or dual 120/dual 140.
     
  15. PhatKat

    PhatKat Banned

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    You know it!
     

  16. NoviceRei

    NoviceRei Ancient Guru

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    dremel. i know it's kind of a big investment, but if you're into modding that much a dremel is an invaluable tool.
     
  17. Hav0q

    Hav0q Master Guru

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    Wow, so I was talking to a friend about my project and he referred me to a local shop...they'll not only supply me with a high quality polycarbonate sheet to match my 800D's but they'll cut out any size hole and make bolt holes too for only $20? Really? That's cost of the 18x24" sheet of lexan I bought @ Home Depot!
     
  18. Pablo

    Pablo Ancient Guru

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    i would get it done, before he changes his mind, seems a fair deal to me.

    how much is $20 in real money, am sure thats only about 30p or something.

    ok £15 , but you know what i mean.
     
  19. dmak

    dmak Master Guru

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    I would highly recommend finding a bulk supplier of sheet plastics, not a local shop. I have picked up 8x4 (feet) sheets if 1/2 inch acrylic for 100 or less
     
  20. maxfly

    maxfly Ancient Guru

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    thats a sick deal, be sure to post up some pics of it!
     

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