How to Cut Square holes into Plexiglass?

**Hellfire** · Moderator Joined: 05 Aug 2003 Posts: 2961

Want to do a little mod on a case, but need square/rectangle holes for some brackets to go through. What's the best way to do this?

**Dr. EvilCheeze** · Posted: Tue, 27 Jun 2006 18:22:35 Post Subject:

A square drill bit.

OK, since that really doesn't work (too bad... would make life easy).

1) Sketch out the hole on the Plexiglas
2) Drill holes on each corner.
3) Using a hacksaw/jigsaw or maybe a router cut out the pattern.

At least that's how I've done it in the past with wood things.

Das Capitolin · Posted: Tue, 27 Jun 2006 18:45:54 Post Subject:

EvilCheeze has a good idea.

I would do things differently because I have a Dremel, and can simply use a cutting wheel.

Tweaked · Rated PG Joined: 27 Jun 2006 Posts: 4

I deleted my initial post, I guess I posted before asking the appropriate questions.

1. What is the squares dimensions?

**Hellfire** · Moderator Joined: 05 Aug 2003 Posts: 2961

I have a dremel as well, but the square holes need to be so tiny a cutting wheel won't do the job...they need to be about 1cm x 1cm...

Took EC's advice a bit, and just used a drill bit to do the cutting....didn't come out square, but doesn't need to be perfect, won't be seen unless I take the door off Razz

Now when I decide to do a final piece I'll have to try to make it a bit neater...screwed up the piece of plexi i have, so wanted to try something different...tomorrow will get a fresh piece and try again...

Bad thing I found is the dremel tends to melt the plastic when cutting it...maybe have to get a hacksaw like ec said....

Thanks for the advice, now to figure out how to attach it....super glue to the rescue! No, actually going to use some double side foam tape so I can remove it if it doesn't work the way I want it to Grin