Got a slight problem - need to cut a couple oval holes in a piece of thin (0.080") Plexiglas, and am looking for the best way to do it. The Plexi is thin enough that a coping saw would have problems (even a fine-pitch blade wouldn't have 3 teeth in contact, so it would get stuck in the gap between teeth), and because they're interior holes the standard "score and snap" method won't work. Any ideas?
The particular project is fitting a portable air conditioner to my window - needless to say I want to get it done SOON. The hard part of fitting an A/C unit is sealing the gaps, so I figured the easiest way to seal it would be to take the glazing out of one of the sliding sections (aluminum frame) and put in acrylic glazing with the same size holes as the adapter plate (meant to be screwed in place on wood window frames) supplied with the unit. After all, the window frame DOES have weatherstripping to seal it when closed.
My ideas so far:
- Trace the hole from the adapter plate, go over the lines using a craft knife. Lightly at first so I've got more control, then as they get deeper (so that the blade will have a harder time jumping out of the cut) using more force. Once I've got a significant distance (at least a third of the way) into the plexi, try *CAREFULLY* bending along the scored line to break it (and hope I don't ruin the piece).
- Drill a series of small (1/16") holes inside the line really close together, break along the perforations, and file to size.
- Buy a hole saw of the appropriate size, use it to cut the round ends, then score and snap the straight lines connecting the holes.
If anyone else has ideas, thanks in advance.
The particular project is fitting a portable air conditioner to my window - needless to say I want to get it done SOON. The hard part of fitting an A/C unit is sealing the gaps, so I figured the easiest way to seal it would be to take the glazing out of one of the sliding sections (aluminum frame) and put in acrylic glazing with the same size holes as the adapter plate (meant to be screwed in place on wood window frames) supplied with the unit. After all, the window frame DOES have weatherstripping to seal it when closed.
My ideas so far:
- Trace the hole from the adapter plate, go over the lines using a craft knife. Lightly at first so I've got more control, then as they get deeper (so that the blade will have a harder time jumping out of the cut) using more force. Once I've got a significant distance (at least a third of the way) into the plexi, try *CAREFULLY* bending along the scored line to break it (and hope I don't ruin the piece).
- Drill a series of small (1/16") holes inside the line really close together, break along the perforations, and file to size.
- Buy a hole saw of the appropriate size, use it to cut the round ends, then score and snap the straight lines connecting the holes.
If anyone else has ideas, thanks in advance.
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