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Thread: Help! How to make a plexiglass case

  1. #1
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    Help! How to make a plexiglass case

    I am going to make a plexiglass case for my epia 800. Got a few Questions:

    1. What kind of glue do I use to hold it together?
    2. How thick of plexiglass should I use?
    3. What is the best method to cut? I have cut before but its never as straight as I wanted it.

    Thanks.

  2. #2
    FLAC mp3z24's Avatar
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    Re: Help! How to make a plexiglass case

    Originally posted by e36mp3
    1. What kind of glue do I use to hold it together?
    There are adhesives designed for gluing plexiglass, acrylic, lexan, etc. some are available at the hardware store, but most are not. if you have a plastics or glass shop near your town i would suggest tapping them for some info, and they may sell adhesives.

    Originally posted by e36mp3

    2. How thick of plexiglass should I use?
    depending on how you plan to layout the case, you should be able to use 1/4 inch. 3/8 inch would be a good base, and if you need beefy walls, use the 3/8 inch. it will probably be a bit "overbuilt" but, you dont want the thing to fall apart or break if something hits it.

    Originally posted by e36mp3
    3. What is the best method to cut? I have cut before but its never as straight as I wanted it.
    i have seen it cut with a table saw with a fine tooth blade. remeber this though... the spinning blade will melt the plastic if you go too slow... or tear it up if you go too fast. so take your time, and make cuts a little at a time. or, if you have a definate plan, any good glass/plastic shop will cut to dimensions you give them. plus they make the straight and smooth. you can use a dremel or other rotary tool to make cutouts for plugs, fans, etc.

    check out some of the computer mod sites on the net. there are many step by step tutorials on how to make a plexi case.

    best of luck.

    ~Mike
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    I'm sorry, and you are....? frodobaggins's Avatar
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    For the tablesaw, you can also turn the blade backwards
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    Does it really have to be that thick? 1/4"?
    I was thinking of making it really thin, kinda like 1/8" all around. And cutting it by running a razor blade up and down it some time then snapping it. Would that work?

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    Re: Help! How to make a plexiglass case

    Originally posted by e36mp3
    I am going to make a plexiglass case for my epia 800. Got a few Questions:

    1. What kind of glue do I use to hold it together?
    2. How thick of plexiglass should I use?
    3. What is the best method to cut? I have cut before but its never as straight as I wanted it.

    Thanks.

    1. Dont use glue, too messy. And it's too easy to come across the wrong glue even though the package may say "acryllic, plastic, glass, ect..."
    Use "Flex-Fold 2 Continuous Hinge"


    2. If it's a rectangular case, the base and the long sides should be thicker. And the top and short sides should be thinner.

    3. The best way to cut a straight line is to use a Dremel with a router attachment along with a straight edge. The plexiglass will never melt to the router bit. And the bit will chip off any excess melt so you'll have a nice rounded edge. Everytime i goto the hardware store to get mine "professionally" cut, it's almost never cut at 90' angles.

    The flex-fold hinges are great. If you ever want to take apart the case (maybe to add a case fan), it's very easy. And they create rubber feet so they dont slip or slide in the car.

    This site has info on almost every plex-glass accessory
    http://www.tapplastics.com/plastics/.../supplies.html

    another method is to coat the outside of a box or in a mold with fiberglass resin or surfboard resin. It's very easy to mix the chemicals and just apply and let dry. If you tend to mess up with acryllic too much. This is a much cheaper way to go.

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