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Thread: How to cut perfect rectangle in plastic plate?

  1. #1
    Variable Bitrate Hark's Avatar
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    How to cut perfect rectangle in plastic plate?

    I have a plastic switch plate (about the size of a radio faceplate) that is 1/8" thick that I want to cut an inner rectangular hole in, which will essentially make the plate a frame (maybe a centimeter wide all around).

    My question is what's the best way to do this, with the end result being a rectangular hole with perfectly straight lines/sharp corners? I've been using a thin fine-tooth hacksaw blade, and the cuts aren't straight.

  2. #2
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    If you have access to a bridgeport, you can use an endmill and sharpen the inside corners with a file. It will be a perfect rectangle.

  3. #3
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    I bought a Dremmel and it had a router attachment. You can make up a jig to run it against to cut out a perfect Triangle ... oops, circle ... oops , octagon ... Rats, you know what I mean,

    lol

  4. #4
    Variable Bitrate kmcniece's Avatar
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    There is a company that will do Custom fpanels/plates for pretty cheap. I can;t remember the name, but i will look it up for you when I get home late tonight. IIRC, they will laser cut plastic and metals for you, kind of like Emachine shop, only cheaper and only 2D pieces.

    Edit:
    www.frontpanelexpress.com

    Otherwise, a router/dremel w/router attachment would be the way to go. Actually a bridgeport would work as well... You got options..... a hacksaw though, no thanks.
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  5. #5
    Variable Bitrate Hark's Avatar
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    Wow, what a great link - thanks!

  6. #6
    Newbie agmsd's Avatar
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    That's a nice link... anyone knows another link for someone who does plastic?! it would be nice...

  7. #7
    Variable Bitrate kmcniece's Avatar
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    www.emachineshop.com does plastic. I thought front panel did plastic as well.
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  8. #8
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    nice sites

  9. #9
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    Really all you need is a router. Start by making your template out of mdf. Then once you have the shape you want, attach the piece of plexi to the wooden template with double sided tape, and run it around your router. That is how I did the plate on my console.

  10. #10
    Variable Bitrate
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    or, if you're patient, you can use a hacksaw and rough cut it, then fine tune it with a file. That's how I did my aluminum bezel..but depending on the plastic it might be too flimsy to file.......

    mine as well give it a try though if you already started with a hacksaw.
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