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  1. #1
    Member BPM's Avatar
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    How do I cut circles/curves in Lexan?

    I have a sheet of Lexan that I need to cut a 4" circle in. The only tools I have are a Dremel and a hand drill (yay for apartment living ). Any ideas?
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  2. #2
    Member toyomatt84's Avatar
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    Holesaw drill bit. They make them up to 8" if I'm not mistaken. The bit should look like a big bowl and have a serated edge.

  3. #3
    Member BPM's Avatar
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    Quote Originally Posted by toyomatt84
    Holesaw drill bit. They make them up to 8" if I'm not mistaken. The bit should look like a big bowl and have a serated edge.
    Ok, that's what I was thinking of, but I don't ever recall seeing one that big. I'll look again!
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  4. #4
    The Half Asleep Member Stedeman's Avatar
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    A hole saw is one of the best ways but the Dremel with the spiral saw bit and hole attachment would do too.

    [Me doing a Tool Man Rant]Apartment living is no excuse for not having enough tools! I live in a 900 sq ft apartment with a wife and 5yr old daughter and I have a router, table saw, Dremel, full size work bench (fits perfectly in my sliding door hall closet), 4+ tool boxes, 2 drills, torch, and a boat load more. A man for no other reason than being a man must collect tools! Where there is a man and tools there is a way! [End Tool Man Rant]

  5. #5
    Registered Easybeat's Avatar
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    Quote Originally Posted by Stedeman
    A hole saw is one of the best ways but the Dremel with the spiral saw bit and hole attachment would do too.

    [Me doing a Tool Man Rant]Apartment living is no excuse for not having enough tools! I live in a 900 sq ft apartment with a wife and 5yr old daughter and I have a router, table saw, Dremel, full size work bench (fits perfectly in my sliding door hall closet), 4+ tool boxes, 2 drills, torch, and a boat load more. A man for no other reason than being a man must collect tools! Where there is a man and tools there is a way! [End Tool Man Rant]

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  6. #6
    Member BPM's Avatar
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    Quote Originally Posted by Stedeman
    A hole saw is one of the best ways but the Dremel with the spiral saw bit and hole attachment would do too.

    [Me doing a Tool Man Rant]Apartment living is no excuse for not having enough tools! I live in a 900 sq ft apartment with a wife and 5yr old daughter and I have a router, table saw, Dremel, full size work bench (fits perfectly in my sliding door hall closet), 4+ tool boxes, 2 drills, torch, and a boat load more. A man for no other reason than being a man must collect tools! Where there is a man and tools there is a way! [End Tool Man Rant]
    I looked on the Dremel site and it looks like to even use the cirlce cutter, I'd need the High Speed rotary saw instead of the regular Multi-Tool that I have now. While I'd love to own more tools, now is not the time for me to be upgrading my collection
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  7. #7
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    what would happen if you cut a jig in the pattern you wanted from plywood, then clamped it to the lexan and attached a dremel cutting bit to your drill. thats what i did to drill my fan holes for my case, worked like a charm and saved me 12 bucks (cost of a hole saw)


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  8. #8
    Member wannaoc's Avatar
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    Be careful when cutting with a hole saw though. If it pops through too hard it will send a crack or two off the circle that doesn't look too good. Make sure to have some support behind it, that helps defeat this.

  9. #9
    Member cack01's Avatar
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    Lexan won't crack, but you do need to make sure you clamp it b/c the darn thing is going to want to take off on you.
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  10. #10
    Helpful Senior Member Captain Slug's Avatar
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    Does it NEED to be polycarbonate? Because you can order discs or acrylic cheaply from McMaster or USPlastics
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  11. #11
    Member Ramlaen's Avatar
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    router with a straight bit is the best way to cut lexan. Just set up guides for the router to follow.
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