Forum: Search: FAQs: Links: MVPs: Menu. Lexan will crack but most of my experience with that was mounting holes for lexan motorcycle windshields where you are drilling a 1/2-3/4" hole for the rubber or plastic mountings. Mark on the cardboard where you’ll make the hole, with the marker. So I'm thinking Lexan for small holes would probably be forgiving. Diamond drill bits are a perfect choice for drilling through your plexiglass no matter its thickness. Plexiglass is a material that is commonly used in place of normal glass for a number of applications. Attach the drill bit for glass to your drill. Learning how to drill into plexiglass will prevent common mistakes that can ruin the surface.. Use the painter’s tape to attach the cardboard over the area where you’ll drill. With a 0-degree rake and 60-degree points, these bits will come in handy in enabling you to drill multiple layers. If you need to drill through the middle of a large mirror or something, you’ll need a hand drill and a VERY steady hand. This chip forms as the drill advances through the polycarbonate material. I prefer diamond hole saws in a drill press. Larger tip angles commonly cause cracking and blow out as the bit exits the sheet. Drilling a hole (like for a screw, or to start a hole for the jigsaw) can cause it to shatter if you don't use the correct drill bit. Lexan Cracking. Maintain drill feed pressure sufficient to form a continuous spiral-shaped chip. Tip: Cutting plexiglass to size is a simple process, but often leaves the piece with very rough edges. Step 1 Drill holes in the plexiglass at the points that you want to put bolts or screws through it to attach it to another medium. Prepare. Plexiglass is the original acrylic brand which is why many people know acrylic as plexiglass, similar to Americans calling facial tissues Kleenex. Drill a small hole first slowly as the acrylic does like to snatch the drill and the bigger the hole the worse it gets. Tip angles on standard drill bits are commonly 118-130°. Always support the acrylic sheet with a scrap piece of wood that you don't mind drilling holes into. This will allow the bit to easily enter and exit the acrylic without chipping. Use air or water for a coolant if the drill bit becomes hot enough to melt, rather than cut, the polycarbonate. Cutting plexiglass requires patience and the right glass cutting tools. Glass is a slippery material, starting out by drilling into cardboard will help your drill bit get a better grip. Plexiglass will crack even when you use a center punch lightly near an edge. Use this guide to learn the best way to cut plexiglass and the right tools to use for plexiglass sheeting of different thickness. When cutting plexiglass, leave the film in place as long as possible to avoid marring the surface. Gradually increase the drill size and drill slowly with very little pressure. Insert an acrylic point drill bit into the chuck of the drill and set it … These bits contain diamond dust coatings which ensure the cutting edges are sharp. Here’s a diamond hole drill cutting through ceramic for a light fixture I made. This point angle must be ground to 60-90°. thread712-304036. Lexan Cracking Lexan Cracking ... "The most important factor to consider when drilling Lexan sheet products is the heat generated during the actual process. It’s durable, yet lightweight, making it perfect for both residential and commercial buildings. Always support the acrylic does like to snatch the drill advances through the polycarbonate.! Than cut, the polycarbonate material a scrap piece of wood that you n't. Material, starting out by drilling into cardboard will help your drill to your drill bit becomes hot drilling lexan without cracking! 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