Plexiglass Help/Question

[Tristan Lall]

It looks like you're using it for the bottom of the tank, right?

If so, you might want to just use a belt sander to make the rounded corners—you'll get a cleaner finish than with a Dremel, because you'll be removing material as it heats up, as opposed to just melting it due to all the friction from using the slitting wheel on the Dremel. If you can't get it cut precisely to the size you need, get something oversized, and then score and break it, rather than trying to cut material off with the Dremel, in a long pass. Or put it on a table saw. In general, trying to cut a straight line with a Dremel is an exercise in frustration, and won't likely be pretty.

By the way, acrylic can be laser-cut...if you know of any place that can do it, you might be able to convince them to do it cheaply.

[Joe Matt]

Thanks Tristan.

I'm looking into other options besides the Dremel, the reason why I brought it up was because the guy who created the page used one. I don't know if I can get a hold of a table saw (I'll ask my dad) or a laser cutter (again, Dad!) but I'll see what I can do. Yes, it's for the bottom of the tank.

[Tristan Lall]

Now that I think of it, the table saw might create some problems, if you don't have just the right blade, and a solid method to hold down the workpiece. Acrylic can shatter easily, and using a common saw blade probably won't work too well. Polycarbonate, on the other hand, cuts nicely.

[Gabe]

You could also use a band saw or a jigsaw (orbital saw). The jigsaw will work, but the trick is to use the finest tooth blade and sandwich the plastic between scrap pieces of plywood to keep the Plexiglas from chattering and cracking. Then take your time to cut slowly and at a steady pace until completed. This is how I cut Plexiglas acrylic sheets in the shop.
As always, try this method or any method on a scrap piece of plastic to see if it works.