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  #1  
Old 01-24-2020, 12:22 AM
guido guido is offline
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Default Working with acrylic

The windows on my Windbreaker are shredded. I have been thinking that if I can route a flute in the edge of some .220" acrylic sheet that it might just snap into the wire window frame without the need of any fasteners.

Made a crude cutter for the router table. If I can keep the tool speed down and the material feed up it may just work without turning this into a molten mess.

If anyone has some tips in working with this material please chime in.

Thx
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File Type: jpg cutter1.jpg (21.5 KB, 175 views)
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Old 01-24-2020, 08:31 PM
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john hall john hall is offline
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I hate machining acrylic. Its very brittle and will break/crack/melt. Is using Lexan (polycarbonate) an option? If you must use acrylic, keep the tool and workpiece clamped securely. The tool needs to be sharp, but not so much it grabs the workpiece. Not sure if what you are trying will work at all on a router table--fast RPM, no coolant, the workpiece is not clamped. Good Luck.
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  #3  
Old 01-24-2020, 11:22 PM
guido guido is offline
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Thx for the input John.
I know what you are meaning about work holding. No way to hold the piece down for this operation. I'll just have to take multiple light passes and hope for the best. I read somewhere than freezing the material may help.

I may have to rethink my cutter. My original thoughts wear aimed at chip evacuation.
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Basket Cases: 129, 1450 sold, 1650
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Old 01-27-2020, 09:27 PM
guido guido is offline
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One down. One to go. Had to really turn down the router and feed it slow. Still need to cut out for the hinges and come up with some sort of retainer clips just in case. Don't want these widows popping out at the most inopportune time.
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File Type: jpg window4.jpg (20.4 KB, 126 views)
File Type: jpg winow5.jpg (22.6 KB, 126 views)
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Basket Cases: 129, 1450 sold, 1650
125: 48" Mower Deck, Windbreaker Cab
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147: 3 turn steering gear, Spring Assist, QA36a w/Xtreme Motorworks Wings
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Old 01-27-2020, 10:07 PM
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ol'George ol'George is offline
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Acrylic is brittle, be careful drilling holes near edges.
When the drill punches through, it grabs and tends to spall or bust out.
When building guarding, we went to lexan (polycarbonate) as it will cut on the shear and bend in the brake as well as drill/tap without breaking.
As far as edges, we rounded them with a rasp file and hit the edges quickly with the acetylene oxy torch with neutral flame, making them smooth like they were never cut and clear, giving a nice looking job.
It takes a little practice to get it right, but worth the effort.
---just my experience
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Old 01-28-2020, 08:59 AM
guido guido is offline
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Thanks George, for the words of caution and your insight on this material. I have used it to make guards, covers, and enclosures in the past. Just never did any edge work with it until now.

Did I really need to flute the edge for this? Probably not. But it will stay in place better with fewer fasteners.
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File Type: jpg window2.jpg (8.5 KB, 115 views)
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Basket Cases: 129, 1450 sold, 1650
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127: 3 turn steering gear, Spring Assist, Sleeve Hitch, 48" Mower Deck, Dozer Blade
147: 3 turn steering gear, Spring Assist, QA36a w/Xtreme Motorworks Wings
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Old 02-12-2020, 08:58 PM
Randy Littrell Randy Littrell is offline
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Quote:
Originally Posted by guido View Post
Thanks George, for the words of caution and your insight on this material. I have used it to make guards, covers, and enclosures in the past. Just never did any edge work with it until now.

Did I really need to flute the edge for this? Probably not. But it will stay in place better with fewer fasteners.

That came out great! As a 30+ year auto glass guy, acrylic is a pain in the ass to work with.



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Old 02-13-2020, 11:14 AM
guido guido is offline
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Thx Randy,
It was tedious to say the least.
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Basket Cases: 129, 1450 sold, 1650
125: 48" Mower Deck, Windbreaker Cab
127: 3 turn steering gear, Spring Assist, Sleeve Hitch, 48" Mower Deck, Dozer Blade
147: 3 turn steering gear, Spring Assist, QA36a w/Xtreme Motorworks Wings
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