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Conference unifix::sailing

Title:	SAILING
Notice:	Please read Note 2.* before participating in this conference
Moderator:	UNIFIX::BERENS

Created:	Wed Jul 01 1992
Last Modified:	Mon Jun 02 1997
Last Successful Update:	Fri Jun 06 1997
Number of topics:	2299
Total number of notes:	20724

1191.0. "Cutting a Hole in Lexan?" by SALEM::KLOTZ () Fri Apr 28 1989 10:13

    Hi folks,
    	
    	I am going to add one of those solar powered exhaust fans to
    	improve ventilation while I'm not around.
    
    	I'd like to install it in the hatch (LEXAN?) in the head.
    
    	The question is --
    
    	"Any good ideas on the best way to cut a 4"dia. hole in the
    	 Lexan Hatch?"  (Hopefully without removing it)
    
        Right now I'm leaning toward my saber saw (or router?)
    
               Any thoughts appreciated,
                                    Thanks in advance,
                                                       Lou "Phanta Sea"

T.R	Title	User	Personal Name	Date	Lines
1191.1	a hole saw?	MSCSSE::BERENS	Alan Berens	`Fri Apr 28 1989 10:35`	5
	A saber saw will not make a very neat hole (a least in my hands). The speed of a router is high enough that there is risk of melting the lexan (which, incidentally, scratches easily). I'd suggest a high quality hole saw, used at low speed and lubricated with water.
1191.2	A fly cutter	AHOUSE::GREIST		`Fri Apr 28 1989 14:37`	13
	A fly cutter in a 3/8 inch variable speed drill would cut a nice 4" hole. Keep the speed low to avoid melting the Lexan. To make sure there is no problem with break out, start the hole from the inside (bottom). After cutting half way through, switch to the other side to complete the hole. This would apply to either a fly cutter or a hole saw. Al
1191.3	Worked out Great!!!	SALEM::KLOTZ		`Mon May 01 1989 14:10`	32
	OK - Here's how I did it: Used the tip in .2 regarding drilling from both sides to make two holes- one very small pilot at the dead center of the hole I wanted and one large enough for a small fine blade jig saw blade the radius of the hole away Added the little device to my jig saw that allowed me to use the smaller hole as a pivot point and adjusted it to the radius so the blade went through the larger hole. I found that at a slow speed things tended to bounce a bit so I ran the jig saw at a high speed with a fairly slow forward motion so the blade could do it's thing. This cut around very well; However, as expected the material did flow - the result was a perfectly round hole that wouldn't come out. Rather than force things I just cut it again - better this time but still re-flowed a bit - SO one more time around and I had a Perfect 4" hole. I used a pen knife to remove a few spots of reflow then ran some fine sand paper around to clean things up. The whole process took about 10 min & FIT LIKE A GLOVE. Thanks for the assistance, Lou
1191.4		WODBOT::GINGER	Ron Ginger	`Tue May 02 1989 13:45`	6
	RE -.2 the suggestion to use a fly cutter in a variable speed drill is dangerous All of them Ive seen very carefully warn touse only in a drill press, and my experience confirms that- even in a press they can shake hard and take control.
1191.5		VLNVAX::FRENIERE		`Tue May 02 1989 14:40`	4
	amen to .4 from 8 fingered and one eyed Don