Drilling Through Acrylic!

[Joe Cygan]

All real good suggestions. My findings is the right drill bit, mask it off and take your time. You don't want to melt the acrylic but you don't want to chip/punch through either..In reference to the square cuts..I drill 4 holes and use either dremel/scroll saw and file it. I would like other suggestions if they make a square bit.

Yup, I'm a dork! I thought you meant for cutting square plastic pieces not squares in plastic. Obviously the reply below I gave was for the square plastic pieces. In this case mlscotti is right with the drill method and probably a file to clean up.
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Don't waist your time with this procedure, just use a band saw with a metal cut blade at medium speed, right?

Joe

[No Longer Active]

just use a band saw with a metal cut blade

I guess only a handful of builders would have these!

[Joe Cygan]

I guess only a handful of builders would have these!

Hi Alex,
Actually just go to your local hardware store and pick up a small band saw for $100 and a $6 dollar metal cutting blade. Better yet you can find used ones on e-bay all day long for half that, in the states anyway.

I could not imagine building a cockpit without one of these tools. Saves a ton of time.

Joe

[cscotthendry]

All real good suggestions. My findings is the right drill bit, mask it off and take your time. You don't want to melt the acrylic but you don't want to chip/punch through either..In reference to the square cuts..I drill 4 holes and use either dremel/scroll saw and file it. I would like other suggestions if they make a square bit.

In fact there IS such a thing as a square drill bit

Check this out

http://blog.makezine.com/archive/200...h_a_watts.html