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Thread: Building a plexy case...

  1. #1
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    Post Building a plexy case...

    I find it very hard to cut some decent looking rectangular holes at the back of my plexy case for the various I/Os (parallel/serial/usb ports, ps/2, etc...).
    I make some small holes with a drill for a start at the corners and then I use a Dremel tool with a cutting wheel to connect them, but I already destroyed 2 sheets of plexiglass.
    Could you suggest a better/proven technique?
    Also, any ideas on how to mount the PCI cards?

    Dimitris

  2. #2
    FLAC LESLIEx317537's Avatar
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    I am about to make a Lexan case or Plexi glass case myself.
    I would think using a dremel with the correct wheel would be easy. Which cutting wheel are you using? I cut my metal case side with a fiber disc.
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  3. #3
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    Here is what I found works well.... Use a piece of sheet metal as a guide with a thin Dremel attachment such as the engraving tool. At high speeds the thin tool cuts through Plexi like butter because of the friction caused heat.
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    FLAC PatO's Avatar
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    Here ya go:
    http://www.dremel.com/productdisplay...1&Color=99CCFF
    Works like a dream! Used it on my harddrive mod. Even for large cuts where you can't use the arm, it's much easier to not have to hold the spinning, noisy dremel while making precise cuts. The dremel drill press looks cool, too. Haven't tried it, though.
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  5. #5
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    Do you have access to a saber saw? I cut all the holes for my player by drilling holes and then using a saber saw to square the cuts.

    -Jeff
    MPEGBOX - Plexiglass Computer
    www.mpegbox.com

  6. #6
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    Get a laser pointer. Draw two dots where you want to cut between. Very quickly swing the pointer so the red dot goes back and forth between the two dots. This will make a very exact cut, but will take several Millinea
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  7. #7
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    Being that I don't own a dremel I used a soldering gun with a flat head attachment to cut through the plexi. It works like a knife through butter, if you can handle the fumes that is!

  8. #8
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    you can always take it to a plastics company - they should cut all the holes out for you for about $50 and it will come out perfect

  9. #9
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    I took my plexi to a glass/plastic shop, and the guy just ran a glass cutter over the cutting line like 30 times, then folded along the crease to break apart the plexi.

    It wouldn't work for small I/O slots though...that soldering attatchment sounds like a good idea, really smelly/messy though.

    PS: I tried taking a spin saw to the plexi. Even though i was going EXTRA slow once that blade hit the plexiglass it broke off a huge chunk and sent it 40 feet into the air.

  10. #10
    FLAC PatO's Avatar
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    Originally posted by SuperAJ:
    <STRONG>PS: I tried taking a spin saw to the plexi. Even though i was going EXTRA slow once that blade hit the plexiglass it broke off a huge chunk and sent it 40 feet into the air. </STRONG>
    Not that I've tried using a circular saw (or the like) to cut plexi, but I'd imagine you'd need a very fine-toothed blade. Something for masonry or finishing.
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