Window Mod Help

[AKIMbO]

I need opinions/guidance on how to go about cutting an acrylic window. I am going to be bolting the window onto the outside of the case (no 4010 tape here) and therefore want the edges of the acrylic to be very smooth. Should I use a jigsaw or do you think a dremel w/ cut-off wheel will suffice? Will I most likely need to polish the sides of the acrylic that have been cut? I've never worked with acrylic before so any help is appreciated. Thanks.

[ballz0r]

best result just scratch a line using a box cutter and a ruler, then snap the acrylic sheet along this line.

i usually bend the acrylic over the edge of a bench top or table till it snaps.

this way you get no machining marks... if you cut it with a saw or cutting disc youll need to sand for hours

[ballz0r]

i got myself one of these acrylic cutters.... sometimes the box cutters catch an edge and run away from the ruler

http://olfa.co.uk/ds_28-P-800.jpg

[AKIMbO]

Alright...thanks ballz0r. Will I still need to do some minimal buffing if I score & snap the acrylic?

[ballz0r]

Usually none is required

Forgot to mention that cool acrylic snaps cleaner

[jacobroufa]

If you're wanting more than just all straight edges, I would recommend using a spiral cut bit. It takes some getting used to - not the easiest thing to keep under control - but it produces a clean edge, thats for sure.

[uoislame]

I heard you can use a wet saw if you have one. The one I have cuts brick and tile smooth as butter; albeit a bit messy.