Looking for Ideas - Cutting Lexan Disks

[rwanttaja]

I'm trying to come up with a way to easily cut out disks of Lexan to a given diameter.

A fly cutter would be ideal...but I don't want the center hole that a fly cutter normally produces. I want to end up with an unblemished disk of clear plastic. This isn't a standard size, so a hole saw won't work. And since the disks are to fit existing holders, a reasonable amount of precision is needed.

The only thing that comes to mind is to clamp down the plastic and use the fly cutter without the pilot drill. Any other ideas?

Ron Wanttaja

[Frank Giger]

Sounds like you need to modify a hole cutter, which is an arm that comes off a center drill that has two adjustable cutting blade.

The modification is to shorten the center drill to where is it below the cutting edge of the blades. Put a thin sheet of plywood or something on top of the piece you want, clamp it with the plexiglass, and go to town.

https://www.amazon.com/Adjustable-Ho...s_id=256292011

[edit]

Sorry, you mentioned "fly cutter" which is probably the same thing I'm thinking of.

Frank "Why are all your tools ground down?" Giger

[Bill Berson]

Maybe a 3" (or whatever size) disc of 3/4" wood with a pilot hole half inch deep but not all the way through. The disk would fit in a scrap of plywood with a three inch hole.

[Dana]

Band saw?

[FlyingRon]

Holesaw without the pilot bit.

[rwanttaja]

Sounds like you need to modify a hole cutter, which is an arm that comes off a center drill that has two adjustable cutting blade.

[edit]

Sorry, you mentioned "fly cutter" which is probably the same thing I'm thinking of.

Yes, close, but yours at least has two arms. This is what I have:

Holesaw without the pilot bit.

Yes, but hole saws come in specific sizes, and I need something that'll be between the sizes. Their sizes are also the OUTSIDE diameter, and I'd actually be needing a specific inside diameter. Though I'll have to look at my 3" hole saw, the ID might be close.

Band saw?

Part of the problem is that I will probably want to produce several of these, and am hoping to reduce the amount of cutting and filing to fit.

The thread on the P-51 panel got me to thinking about building simulated instruments for a similar replica panel. I used Solidworks to design the instrument bezel, fitting into a standard hole and designed to take a piece of glass/plexiglass/lexan. The problem is, the lip is only about 0.1" wide. Since the simulated instrument has to fit into a standard hole, changing the size to match available tooling isn't really an option.

So I'd love to be able to use a standard setup and crank out a number of these. Once I get the front bezel settled, I'll start working on the back half of the instrument, to include the face and the needle.


Ron Wanttaja

[Jeff Point]

How about a laminate bit in a router? Use other tools to make a template disc out of Al or plywood and duplicate it in plexi using the laminate bit. Carpet tape could attach the plexi blank to the template.

[martymayes]

I'm trying to come up with a way to easily cut out disks of Lexan to a given diameter.

Any other ideas?

Stack them in a lathe between centers and turn them. I have done this before and it works very well, the OD can be turned to +/- .005" without too much effort.

[mmarien]

I've been using a CNC router for a few years for my Hatz build. I have cut plexiglass, wood and now aluminum. Depending on the max size you want to cut, a small 12"x24" CNC router will cost less than $500. It's my most versatile tool. Some projects:



Wood nose pieces for the wings.



Elevator trim handle cut from 1/8" aluminum



Elevator trim built from aluminum



Face plate for elevator trim cut from plexiglass.



Throttle quadrant made from aluminum.

[Frank Giger]

My WebFu is weak, sir, so if you could tell me which machine you got I'd be much obliged.