Routing Lexan?

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D'Ecosse

Copper - Posts: 49

Joined: October 24, 2004

Posted: October 25, 2004 at 1:35 AM / IP Logged

Anyone routed Lexan? My friend needs some louvre slots cut in a rear window /engine hatch. I don't think it will be a problem, but any advice would be appreciated re cutting speed etc. I figured I'd try to keep the bit speed down a little, keep the tool moving & try to "bite" as little as possible. I'll lay out the pattern on MDF and just use that as a template with a pattern cutter.

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Alpine Guy

Platinum - Posts: 2,478

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Joined: October 18, 2003

Location: Canada

Posted: October 25, 2004 at 8:49 PM / IP Logged

i seen on tv where the guy took a razor blade, , "very sharp one" Cut the lexan as deep as possible in 1 or 2 passes,,,then pour alcohol in the groove, , light it on fire and bend it off. It cuts perfect. But that was for big curves and straight lines, , , if its a really tight curve, then that prolly wont work.

2003 Chevy Avalanche,Eclipse CD7000,Morel Elate 5,Adire Extremis,Alpine PDX-4.150, 15" TC-3000, 2 Alpine PDX-1.1000, 470Amp HO Alt.

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chrane

Member - Posts: 27

Joined: October 18, 2004

Location: Canada

Posted: October 26, 2004 at 8:50 PM / IP Logged

lexan is easy to router, but get a friend or hire an imigrant to spray wd-40 on the blade and the plastic every 2 seconds or so to keep it cool so it cuts smooth

Aaron

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CarAudioHelp

Copper - Posts: 198

Joined: July 18, 2003

Location: United States

Posted: October 27, 2004 at 8:50 AM / IP Logged

You've got the right idea with the MDF pattern. A tip to improve and reduce your finishing time. Make two templates, one about 1/16" bigger than your finished template. Route to that line first and then go back and finish off with the correctly sized template. By removing only a small layer on the final pass you will get less chipping which means less sanding/buffing.

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D'Ecosse

Copper - Posts: 49

Joined: October 24, 2004

Posted: October 27, 2004 at 9:29 AM / IP Logged

CarAudioHelp wrote:

...Make two templates, one about 1/16" bigger than your finished template. Route to that line first and then go back and finish off with the correctly sized template. ....

That's a great tip! Thanks!

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Routing Lexan?

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