Plexi

[wd4lc]

I'm in the middle of building a little case. I basically have two half-blind jointed squares of wood. I'm going to join these with hinges. On the bottom portion, I'm going to dado the sides and slide in some plywood. I would like to dado the top square and add a piece of plexi (or acrylic type substance).

Lowes has a small section of the stuff. The 1/4" is more expensive than I was expecting. I need this thickness because it's stable and the smallest router bit I have is 1/4". Previously I had thought about using a thinner piece of plexi and trying to dado the wood with simply the table saw blade itself. However, the plexi is way to flexible and wouldn't support anything anything inside the case or anything resting on top of it. I feel as thought the 1/4" would be the smarter route.

Any thoughts on where to find cheaper plexi. Or any thoughts on other clear materials. I've been trying to think outside of the box. Even thought about buying a clear plastic tote, cutting the side out and using that as a lid.

Thx.

[cabinetman]

What about glass?

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[LarryG]

Try a local glass shop. Most of them will usually have plexi or Lexan. If the piece you need is really small, you might be able to buy a scrap for little or nothing and cut it to size yourself.

[pelligrini]

Glass would probably be better, even 1/4" plexi will warp. Glass is fairly easy to cut too.

A broke a part of an aquarium hood and then used a 6"x36" piece of 1/4" plex for a fix. It warped in a matter of days.

[LCHIEN]

glass is probably what you want, not much more expensive, a little harder to cut (they have glass cutting knives) but you can have the glass shop cut it for you. They may have cutoffs for real cheap.

[cabinetman]

glass is probably what you want, not much more expensive...

Actually glass would be less expensive.

a little harder to cut (they have glass cutting knives) but you can have the glass shop cut it for you.

IMO, cutting glass is easier than cutting cast acrylic or polycarbonate. The tool is usually just called a "cutter".

They may have cutoffs for real cheap.

In the trade, glass cutoff's are called "drops".

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[wd4lc]

Thanks. I'll consider glass. I had thought about that but didn't want something breakable in there and figured cutting it would actually be harder. However it sounds like it's easier. I actually have some old, small window panes. If I can find a way to join 6 of those together and then cut off the ends that would be great. It would be free and a good way to re-use them.

Thanks again. I'll buy a cutter and test out the glass thing Also look for some window, glass or even frame shops to see if they have "drops" of glass or spare plexi.

[Denco]

If you decide to stay with plexiglass/plastic stuff, Tap Plastics may be an option. If you don't have one near you, here's their web address: http://tapplastics.com/

[LCHIEN]

cutting glass is not real difficult or requiring expensive or complex tools. Just takes a little more technique than cutting plexiglass on a table saw though.

Basically you need a glass cutter, a $10 tool which has a carbide scoring wheel. You need to press the scoring wheel against the glass (the amount of pressure is somewhat critical) using a straightedge and make a scratch in the glass surface, Then take the glass in your hands like a breaking a saltine cracker along the dots and gently twist along the score and the glass will break cleanly along the score. takes a little touch with the scorer and again when breaking the glass. Here's a detailed procedure:

http://www.wikihow.com/Cut-Glass

if you have several scrap pieces of glass to practice on that would be ideal.

[Poobah]

I was able to get two 11x14 plexiglas pieces for free at Lowes. They tend to have a stack of cutoffs leaning against the wall at the cutting station. Might get lucky if you see what they have

[radhak]

What size do you need?

I actually have some old, small window panes. If I can find a way to join 6 of those together and then cut off the ends that would be great

Were you thinking of joining glass panes? I was not aware one could do that.

[cabinetman]

cutting glass is not real difficult or requiring expensive or complex tools. Just takes a little more technique than cutting plexiglass on a table saw though.

Basically you need a glass cutter, a $10 tool which has a carbide scoring wheel. You need to press the scoring wheel against the glass (the amount of pressure is somewhat critical) using a straightedge and make a scratch in the glass surface, Then take the glass in your hands like a breaking a saltine cracker along the dots and gently twist along the score and the glass will break cleanly along the score. takes a little touch with the scorer and again when breaking the glass. Here's a detailed procedure:

http://www.wikihow.com/Cut-Glass

if you have several scrap pieces of glass to practice on that would be ideal.

Cutting glass is not difficult, and successful cuts become a "feel" for the amount of pressure needed. On clean glass it's just enough pressure to produce a score.

The best cutter I've ever used is a plastic oil filled handle, like this one. It also has a replaceable cutting wheel head.

For a straightedge, I make Plexiglas ones like this, which will provide for a long score line. It's easy to make. It's basically an "L" square, that just aligns along the bottom edge of the sheet. Using a grease pencil, lay the edge on the glass, and using the cutter, align the wheel with your mark. Being acrylic it won't scratch the glass, and only slight pressure is needed to hold it in place.

When making the score line start at the top, or the edge furthest from your body, and with a straight edge secured, rock the wheel of the cutter forward and backward one or two times to get the wheel to start right at the edge. Draw the score towards your body, and continue right off the glass.

Separating the glass after the cut can be done as described by holding between the hands. That works OK for 1/8" glass, but thicker pieces need to be "snapped" differently. If you use the edge where the wheel ran off the glass, tap on the underside to produce a crack line, which will run the length of the score.

This works for 3/16" and 1/4" glass and mirror. Using wet-or-dry (silicone carbide) sandpaper...the charcoal grey stuff, on the cut edge will remove the sharpness.

[herb fellows]

If you have not yet decided the dimensions, and you have an Ikea in your area, they almost always have some glass in their 'as is' dept for a couple of bucks. Mostly shelves from pieces of furniture that broke.
It is almost always safety glass. I say almost for caution, I've never seen any that wasn't.
Safety glass can't be cut, so you have to use it in the size you buy.
Hey, it's SAFETY glass, it's almost always 1/4", and you don't have to cut it!

If you do go the cutting glass route, use a little kerosene or oil (almost any kind will do) on the cutter. Be sure to start off the edge and go all the way through.
Never re-cut the line, it simply doesn't work. One shot is what you get.
Any diamond tool bit can be used to smooth the edges, from a Dremel bit to whatever. By hand will work also with anything diamond.

[cabinetman]

It is almost always safety glass. I say almost for caution, I've never seen any that wasn't.
Safety glass can't be cut, so you have to use it in the size you buy.
Hey, it's SAFETY glass, it's almost always 1/4", and you don't have to cut it!

"Safety glass" is also called "tempered glass". If it is it will have an embedded label in one corner.

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[wd4lc]

cutting glass is not real difficult or requiring expensive or complex tools. Just takes a little more technique than cutting plexiglass on a table saw though.

Basically you need a glass cutter, a $10 tool which has a carbide scoring wheel. You need to press the scoring wheel against the glass (the amount of pressure is somewhat critical) using a straightedge and make a scratch in the glass surface, Then take the glass in your hands like a breaking a saltine cracker along the dots and gently twist along the score and the glass will break cleanly along the score. takes a little touch with the scorer and again when breaking the glass. Here's a detailed procedure:

http://www.wikihow.com/Cut-Glass

if you have several scrap pieces of glass to practice on that would be ideal.

Thanks, LCHIEN. I watched a couple of videos the other day on cutting glass and was very surprised at how easy it actually is. As you mentioned it just takes a simple cutting tool (preferably with oil reservoir).