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
1. What kind of glue do I use to hold it together?
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
2. How thick of plexiglass should I use?
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.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.
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.