Results 1 to 10 of 10
  1. #1
    300+ Forum Addict Rodney's Avatar
    Join Date
    Nov 2005
    Location
    Colorado Springs, CO USA
    Posts
    332
    Contribute If you enjoy reading the
    content here, click the below
    image to support MyCockpit site.
    Click Here To Contribute To Our Site

    Holes in Plexiglass

    I am going to need to cut some different sized holes in some 1/4 plexiglass and wonder what others experience in this is. I have all types of hole saws that are primarily designed for wood. I have not found any other type hole saw. My concern is getting a clean cut hole. Any suggestions?

    Thanks in advance!
    Rodney -
    Real 727-200 pit
    Last Flown as N392PA
    FS9

  2. #2
    2000+ Poster - Never Leaves the Sim Trevor Hale's Avatar
    Join Date
    Nov 2005
    Location
    Ontario, Canada
    Posts
    2,223
    Contribute If you enjoy reading the
    content here, click the below
    image to support MyCockpit site.
    Click Here To Contribute To Our Site

    Quote Originally Posted by Rodney View Post
    I am going to need to cut some different sized holes in some 1/4 plexiglass and wonder what others experience in this is. I have all types of hole saws that are primarily designed for wood. I have not found any other type hole saw. My concern is getting a clean cut hole. Any suggestions?

    Thanks in advance!
    Honestly the best type of bits I have used to drill holes in Plexi are Masonry bits.

    The duller the better, I have never tried a hole saw, but that should be fun. I would suggest testing on some practise peices first.

    Trev
    ________________________
    Trevor Hale

  3. #3
    300+ Forum Addict Rodney's Avatar
    Join Date
    Nov 2005
    Location
    Colorado Springs, CO USA
    Posts
    332
    Contribute If you enjoy reading the
    content here, click the below
    image to support MyCockpit site.
    Click Here To Contribute To Our Site

    Trev,
    Thanks. I actually have a "backed off" drill bit made for plexiglass. The holes I'm speaking of are for gauges.
    Rodney -
    Real 727-200 pit
    Last Flown as N392PA
    FS9

  4. #4
    2000+ Poster - Never Leaves the Sim Michael Carter's Avatar
    Join Date
    Oct 2006
    Location
    Southern Illinois, USA
    Posts
    2,887
    Contribute If you enjoy reading the
    content here, click the below
    image to support MyCockpit site.
    Click Here To Contribute To Our Site

    Spade bits work very well in plexiglass. Though I've never seen one as large as 3".
    Boeing Skunk Works
    Remember...140, 250, and REALLY FAST!

    We don't need no stinkin' ETOPS!



    Powered by FS9 & BOEING

  5. Thanks Rodney thanked for this post
  6. #5
    300+ Forum Addict
    Join Date
    Feb 2006
    Location
    N/A
    Posts
    458
    Contribute If you enjoy reading the
    content here, click the below
    image to support MyCockpit site.
    Click Here To Contribute To Our Site

    Plexi Holes

    Rodney,

    I drilled some different sized holes into plexi using both wood and metal, as well as hole cutting bits; you know, the type that are made for door knob hole cutting, but in various sizes. Don't use the variable hole cutter bit that has the adjustable cutter tip. That type of bit flexes ever so slightly, which is okay for wood, but will cause splintering in the plexi Additionally, I've used the wood spade bits that Michael has used without any problems.

    My best advice is to use a drill press to drill the holes and start by drilling pilot holes first. The drill press should be set to a slower speed. Not to slow, but not fast either. Too slow will cause cracking and too fast causes melting of the plexi which will cause cracking as well.

    However, before you start, place some masking or boxing tape on the plexi (before making you measuring marks) to absorb the initial contact of the bits to the surface and thereby, reducing the splintering which causes cracking to occurr.

    Finally, place the plexi onto a piece of plywood (not press or chip board, but a good grade of plywood) that you don't mind wasting and then clamp it all down to the drill press work plate (the plate just below the bit). By the way, dont remove the protective covering until you're ready to use the plexi (the last step in whatever it is your making).

    I hope this helps,

    John

  7. Thanks fweinrebe, Rodney thanked for this post
  8. #6
    1000+ Poster - Fantastic Contributor AndyT's Avatar
    Join Date
    Jun 2006
    Location
    Oahu, Hawaii
    Posts
    1,236
    Contribute If you enjoy reading the
    content here, click the below
    image to support MyCockpit site.
    Click Here To Contribute To Our Site

    Just to restate what John said:

    Cover the area you are going to cut with masking tape first. It prevents many problems as you cut.

    Cut slightly smaller than you need and sand back to your exact measurement. For plex, use a wet sandpaper and go slow with tape on BOTH sides. That will protect your surface as you cut and sand.
    God's in command, I'm just the Pilot.
    http://www.geocities.com/andytulenko/

  9. #7
    300+ Forum Addict Rodney's Avatar
    Join Date
    Nov 2005
    Location
    Colorado Springs, CO USA
    Posts
    332
    Contribute If you enjoy reading the
    content here, click the below
    image to support MyCockpit site.
    Click Here To Contribute To Our Site

    Thanks Gentlemen. I will try with spade and hole saw bits on some scrap this weekend and let you know how it turns out.
    Rodney -
    Real 727-200 pit
    Last Flown as N392PA
    FS9

  10. #8

    Airbus

    Rodney,
    I have cut tons of plexiglass and my experience is keep water on it where your cutting so heat doesn't build up and thats what causes it to crack. JMO

    Tim

  11. #9
    300+ Forum Addict Rodney's Avatar
    Join Date
    Nov 2005
    Location
    Colorado Springs, CO USA
    Posts
    332
    Contribute If you enjoy reading the
    content here, click the below
    image to support MyCockpit site.
    Click Here To Contribute To Our Site

    Well I achieved the desired results using what others said here. Clamp to good plywood, use spade bit, light pressure and mask the hole before drilling. Because I am using a sheet 26" X 25" I could not use a drill press yet with the sheet clamped tight I had no issues. Now to get busy cutting some annunciator holes. Thanks to all of you!
    Rodney -
    Real 727-200 pit
    Last Flown as N392PA
    FS9

  12. Thanks fweinrebe, Matt Olieman thanked for this post
  13. #10
    2000+ Poster - Never Leaves the Sim Michael Carter's Avatar
    Join Date
    Oct 2006
    Location
    Southern Illinois, USA
    Posts
    2,887
    Contribute If you enjoy reading the
    content here, click the below
    image to support MyCockpit site.
    Click Here To Contribute To Our Site

    I was going to mention that if you're not using a drill press because the size of the piece, clamp it as close to the hole you are drilling as is possible.

    When I have to drill on the bench, I use a backing piece then the plexi, and then another piece of plywood very close the the hole all clamped to the wood bench.

    Those spade bits do cut a nice hole, especially for switches.
    Boeing Skunk Works
    Remember...140, 250, and REALLY FAST!

    We don't need no stinkin' ETOPS!



    Powered by FS9 & BOEING

Similar Threads

  1. How can I make the back lighted letters in a plexiglass panel?
    By mirrage in forum Cockpit Parts and Motion Platforms
    Replies: 26
    Last Post: 05-22-2014, 11:11 AM
  2. Plexiglass Cubes
    By Boeing 747 Flyer in forum General Builder Questions All Aircraft Types
    Replies: 13
    Last Post: 12-22-2010, 06:59 PM
  3. Holes for rotary switches...
    By Drewsta in forum I/O Interfacing Hardware and Software
    Replies: 4
    Last Post: 09-30-2010, 09:25 PM
  4. ND / PFD holes measures
    By Anderson/SBSP in forum General Builder Questions All Aircraft Types
    Replies: 3
    Last Post: 10-08-2009, 09:20 AM
  5. Machining plexiglass
    By Westozy in forum Cockpit Parts and Motion Platforms
    Replies: 4
    Last Post: 11-06-2006, 03:21 PM