[Milsurplus] Cutting Thick, Clear Plastic

[Mike Hanz]

David Stinson wrote:

>The plastic is about 1.5 times as thick as a computer CD disc,
>and about the same flexibility; perhaps a bit more.
>

Ah!  Okay, thanks...'thick' to me is anything over an inch.  :-)

>Isn't Lexan much thicker?  
>

Not necessarily - you can get lexan in just about any thickness that is 
available in plexiglas or other clear plastics.

>My hand isn't nearly steady enough to cut a circle cleanly
>with a Dremel tool free-hand.  (Light-bulb just went on)-
>Would this work: fix an arm or "jig" to the center of the circle
>being cut, using it to hold the Dremel tool at the right diameter as 
>I rotate it all the way around.  My concern: even on low speed,
>wouldn't a Dremel get too hot for such thin plastic?
>

Not if you blow on it.  <g>  Seriously, just cut a little and let cool a 
little.  You'll eventually get it all the way around the circle.  I 
think I would cut it to rough shape and chuck it in a hand drill with a 
bolt and a couple of washers.  Use a sanding block to smooth the edge as 
it spins until it's the right diameter.  It will be easier if you hold 
the drill in a vise and leave it turned on - that will allow you to 
control the sanding block more easily.  Finish up with some 400 grit 
wet/dry and it will look fine.

73,
Mike