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Whats the easiest way to cut plexi- glass? i tried using that dremel tool and all it does is melt the plastic...........

 
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Depending on how the cut should be, like straight, or in some sort of shape, you could try to first make cut with a sharp knife, and then break it along that edge. If you make the edge-cut deep enough, you shouldn't have any risk in breaking off to much. But gain this only works for long straight edges and not for complex shapes.

 
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i go to home depot to buy that stuff--they'll cut it to size for free. they use this big machine that scores the plexi glass deeply...then they just break it. it breaks cleanly.
-jro

 
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check HERE

 
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check your yellow pages for waterjet or laser cutting shops...

seriously, waterjet cutting machines kick ***! its like a nozzle on a robot arm that shoots a needle-like jet of water at 50,000+ PSI... watch out for your fingers, lol... but the best part is that for plexiglass, there won't be any melting or rough edges.

waterjets do a great job, they can cut to any size/shape/complexity that you can imagine... i dunno how expensive it would be though... probably not too much for a small, simple project though

 
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you can easily cut plexi yourself, with ANY home tool you have. its a blade you need!

you see, wood cutting blades have what is called a positive rake on them. this makes them look more like ocean waves. this way the blade gets pulled into teh wood, then chews it up.

with plexi, the blade cant cut that much, and will usually end up fracturing.

a plexi cutting blade will have a NEGATIVE rake, where the blade looks more like triangles than waves. what happens is that you basically scratch teh plexi a little bit when it passes, and the action of 7439028493 blades doing this will eventually scrape enough to make a pretty clean cut.

if you are going to be cutting thick plexi, or a lot of it, Id highly reccommend investing in a blade, for whatever saw you have.

in school, we used a table saw with a plastics blade, so you could even use a circular saw if you wanted. just need a blade.

edit: BTW cristo, monte cristo is my fav book, i love every small detail about how dumas wrote it. nice choce of a handle [IMG]i/expressions/face-icon-small-smile.gif[/IMG]

 
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I had the thickest stuff they had at home depot and i just cut it usting a circular saw with a carbide tip it came out perfect (wear eye protection when cutting plastic because of shavings) Super easy. Dremmel spings too fast and just melts it.