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14

FIGURE 6

Flange Trimming Table Router

WITH TEMPLATE

Fixture

Template

TABLE ROUTER (Wood Shaper)

WITHOUT TEMPLATE

Ball Bearing Guiding on Plexiglas® Acrylic Sheet

Router Cutter with Pilot

FIGURE 7

Trimming with a Portable Router

Overhead Air Cylinders Clamp Work

Portable Router

Template

Plexiglas® Acrylic Sheet

Work Table

Drilling

When drilling Plexiglas® acrylic sheet, best results will be obtained using standard twist drills that have been modified, as described below. High-speed steel drills should be used.

Specially ground drills for Plexiglas® acrylic sheet are available from Authorized Plastic Products Distributors.

Modification of Drills: Instructions for Sharpening Bits

Chuck the bit in an electric drill. Insert the bit through a wood or metal bushing clamped to the support rest of an abrasive wheel. The bushing must be clamped so that an approximately 60° total included angle is ground on the bit. With the electric drill operating, insert the bit through the bushing so that it contacts the face of the rotating abrasive wheel, thus grinding a conical point on the bit. See Figure 8A, at right. Remove the bit from the chuck.

Using the side of the rotating abrasive wheel, grind a 0° rake angle on each of the cutting edges. This provides a scraping action rather than a cutting action. See Figure 8B, right.

Then, using the face of the rotating abrasive wheel, grind a clearance behind each of the cutting edges of about 8° to 12°. Do not touch the cutting edges. See Figure 8C, right.

The resultant bit will produce good-quality surfaced holes in Plexiglas® acrylic sheet, and will eliminate the problem of the bottom surface breaking out when the holes are drilled. Pickup of masking paper adhesive will also be eliminated.

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