Plexi-Glass Design for Large Map (50" x 32")

[jp_over]

Friends,

I need some advice on getting 2 sheets of 1/8" plexi-glass cut and drilled for a large 2-sided map display (educational / teaching).

Here's the plan & questions:
1) 2 sheets of 1/8" plexi-glass cut to 52" x 34"
2) 6 x 1/4" holes with 1" clearance from edge as shown in attached graphic
3) fender washers on both sides for all holes and stop nuts

See any issues or have any recommendations? This item will not see rough use but it won't be a static display so it needs to be sturdy.

Thanks!

 

[rharman]

Most any plexi distributor should be able to do the fabrication for you. I had a custom shape cut for a porch cover and it came out great.

 

[James-W]

Most any plexi distributor should be able to do the fabrication for you. I had a custom shape cut for a porch cover and it came out great.

I agree, that is the best way to do it, although there may be a charge for doing it. I had a friend cut some Plexiglas for me one time. He took it to where he works to do it, they have a vertical metal cutting bandsaw and that worked quite well. They also have an edge sander and he sanded the cut edges to make them smooth and straight.

 

[johnnyradiant]

Cutting plexi is not hard nor is drilling all with common tools. This link suggests 1/4" thick or thicker is the magic number to cutting with a table saw instead of scoring with a knife and snapping. I have successfully cut several different pieces in the 1/8 - 3/16 range on my table saw. I've also had great success with a jigsaw. I put masking tape on the base of the saw to avoid scratches. And I have had success with a circular saw, and band saw. Regular metal cutting drill bits and regular hole saws.

https://www.doityourself.com/stry/how-to-cut-plexiglass-with-a-table-saw

 

[timewarp]

1/8" Plexiglas is pretty flexible, I don't think your 6 bolts are going to be enough, I would use smaller bolts spaced about a foot apart around the edges, holes slightly oversize and rubber washers under the fender washers on each side.

 

[cvairwerks]

Think I’d do a double picture frame for the plex and tight fit the gap to prevent the map from moving around in it. Bolts or screws will tend to fracture plex if they don’t have the ability to move as the plex flexes.

 

[James-W]

Cutting plexi is not hard nor is drilling all with common tools. This link suggests 1/4" thick or thicker is the magic number to cutting with a table saw instead of scoring with a knife and snapping. I have successfully cut several different pieces in the 1/8 - 3/16 range on my table saw. I've also had great success with a jigsaw. I put masking tape on the base of the saw to avoid scratches. And I have had success with a circular saw, and band saw. Regular metal cutting drill bits and regular hole saws.

https://www.doityourself.com/stry/how-to-cut-plexiglass-with-a-table-saw

In the past I have used a table saw with a plywood blade to cut plexiglass and it works pretty good, even when cutting thin stuff, but you have to go really slow. I leave the sticky film covering on the plexiglass until after it is cut. But I still think a vertical metal cutting bandsaw is a better tool for doing it.

 

[Marctrees]

Laminating plastic would not be an option ?

Either roll up or on foam board ?

Marc

http://www.onemapplace.com/lammount.html

https://www.google.com/search?q=map.....69i57j0l5.5616j0j0&sourceid=chrome&ie=UTF-8

 

[Marctrees]

Or use your two pieces of plexi and just neatly run folded over duct tape on edges ?

Marc

 

[Marctrees]

Sign companies have that superr lightweight board that is just like corrugated core cardboard, but plastic... used like for political signs.

Pretty cheap.

Then go to Walmart and in the fabric dept get the Warp's super clear by the foot plastic that Grandma uses on her dining room tablecloth.

Put together w the duct tape edge.

Cheap, lightweight, really tough to damage if dropped.

Just some ideas.

I just think the original sandwich of plexi would be really tiring loading in and out of vehicles.

Marc

 

[Marctrees]

OP original idea will weigh approx 16 lbs.

Marc

 

[Marctrees]

1/8 is best cut using straightedge, scoring, and snap method.

Very easy, works great. no pig pen swarf allover.

Use countertop laminate scorer or similar... for small job even razor knige blade w a ground hook... score one side multiple passes, bend backward over sharp workbench edge... sandpaper/ file for cleanup.

The scoring scrapes a square bottom trough, like a micro Dado.

Marc

Watch the video at this first link.........

https://www.homedepot.com/p/Plastic-Sheet-Cutting-Tool-GE-41/202038073



https://www.google.com/search?q=lam.....69i57j0l2.6104j0j0&sourceid=chrome&ie=UTF-8

 

[jp_over]

Thanks for all the replies and great info! I'm going to think it all over for a bit and then make a decision on how to proceed.

 

[LS6 Tommy]

If it's going to be used in a public school setting, you may have to use materials that are fire & shatter rated. The type of Pexiglass used varies and may not be. I'd look into Lexan, too.

Tommy

 

[BillK]

Do you have any local sign companies ? They should have the ability to do it for you and hopefully not hurt you too bad price wise.