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Conference vicki::boats

Title:Powerboats
Notice:Introductions 2 /Classifieds 3 / '97 Ski Season 1267
Moderator:KWLITY::SUTER
Created:Thu May 12 1988
Last Modified:Wed Jun 04 1997
Last Successful Update:Fri Jun 06 1997
Number of topics:1275
Total number of notes:18109

1080.0. "Enlarge circular hole in plexiglass?" by TOOK::SWIST (Jim Swist LKG2-2/T2 DTN 226-7102) Tue Jul 20 1993 13:46

    The lock on my electronics box cover died - I got a replacement
    from the dealer but the new lock is somewhat different and requires
    a bigger hole in the cover.   The old one appears to be about 3/4"
    diameter and the new one requires 1" dia.    
    
    The new lock is much better quality than the mickey mouse old one so 
    I'd like to try to use it.
    
    What is the easiest way, on site, to enlarge a circular hole in 1/4"
    dark plexiglass from 3/4" to 1"?  Can't use anything requiring a pilot
    bit.  Too big for a reamer, too big for a twist drill.  
    
    Whenever I try something like this I wreck the whole thing.   Any
    ideas?
    
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1080.1a suggestionMASTR::BERENSAlan BerensTue Jul 20 1993 13:517
Cut a 1" diameter hole in a piece of wood. Center the hole in this piece 
of wood over the existing hole and clamp the wood (gently) to the 
plexiglas. Enlarge the hole in the plexiglas with a fairly coarse round 
file. You could try a hole saw guided by the hole in the wood, but this 
would be much riskier, I'd think.

Alan
1080.2try this...MIMS::PICKETT_KTue Jul 20 1993 14:049
    Try this:
    Secure a piece of wood to the back (or front) of the cover via
    c-clamps. Start pilot drill in wood and ease down into the pglass.
    
    
    -good luck!
    Kim
    
    
1080.3SALEM::PAPPALARDOTue Jul 20 1993 14:456
    
    Follow the previous methods mentioned using a board with the correct
    diameter hole and then use a barrel stone on the end of a drill.
    
    
                                                             Guy
1080.4TOOK::SWISTJim Swist LKG2-2/T2 DTN 226-7102Tue Jul 20 1993 14:505
    The file meets the "on site" and "low risk" approaches, at the expense
    of some labor.   Sounds good.
    
    Jim
    
1080.5.2 is right onUSCTR1::BORZUMATOTue Jul 20 1993 15:059
    
    .2 IS CORRECT, HOWEVER BEFORE CLAMPING THE WOOD TO THE GLASS,
    
    YOU NEED TO DRILL A PILOT HOLE AND THEN CENTER IT ON THE GLASS.
    
    
    THIS IS THE LOWEST RISK APPROACH.
    
    JIm   (sorry about the caps)
1080.6be cautiousMASTR::BERENSAlan BerensTue Jul 20 1993 17:499
re .1 and .2:

Plexiglas has a tendency to melt when drilling or sawing (hole saw). The 
melted chips can cause the drill bit or hole saw to jam with 
considerable force, more than enough to break the cover. I have found it 
necessary to use very low speeds with a drill press and lots of water 
lubrication to cut a large hole in plexiglas or lexan. I'd be most 
reluctant to try to enlarge your hole by drilling or hole saw. Your 
skill, technique, and luck may differ.
1080.7SALEM::NORCROSS_WWed Jul 21 1993 09:524
    I would also place masking tape as best I could around the 1" circle to
    help to prevent the piece from cracking and getting scratched.  Would
    it be possible to use a router on this?
    Wayne
1080.8or....LEVERS::SWEETThu Jul 22 1993 14:005
    
    I would use the file and take your time. You could just take the
    door off the hinges and bring it to bench to work on.
    
    Bruce
1080.9signed, incompleteUSCTR1::BORZUMATOThu Jul 22 1993 15:3018
    
    I need to clarify something. My recommendation left something out.
    
    I did not mention taking the door off.
    
    I was under the impression......................
    
    I have drilled and enlarged many holes in plexi and lexan.
    
    Using a drill press at its lowest speed and very light pressure,
    
    and of course a new or newly sharpened hole saw it will do the job
    
    just fine.
    
    
    
    JIm
1080.10Use the jigsaw.MPGS::MASSICOTTEThu Jul 22 1993 19:478
    
    I've cut nice holes with my portable jigsaw, a fine scrolling
    blade and on it's slowest speed, checking the blade temp once
    and awhile with my finger.
    
    Ya gotta go easy tho'.
    
    Fred
1080.11You only have 1, right?SALEM::JUNGhalf-day?>>>Fri Jul 23 1993 11:137
    
    
    I'd go with .8! A "rat tail" file and some time. It has to be the 
    
    safest way to go.
    
                             Jeff
1080.12Two hole saw bladesSUBSYS::CHESTERMon Aug 02 1993 13:4911
    Try this.  Use a circular hole saw with two blades.  The first one should 
    be the dia of the exsisting hole.  The second one the dia of the new hole. 
    Stack a washer or two between the hole saw blades so the smaller one
    sticks out.  It will work as the guide.  Use water or light oil as a
    lube.
    
    I just use this methode to change two tranducers from 1.5" to 2". 
    Worked ok for me.
    
    KC