Lexan

I use the same woodworking tools on plastics that I use on wood.
just a little more slower with more eye protection.
(a wood chip in the eye gets soft right away – a plastic chip in the eye is not good).
I would cut the disk to size with the bandsaw and finish with files, rasps, sanders, etc
to get the exact size you need. (a circle cutter on the bandsaw is a valuable tool to have).

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-- there is no educational alternative to having a front row seat in the School of Hard Knocks. --

Lexan is a good choice. As john said, it can be worked with woodworking tools.

-- Gene 'The true soldier fights not because he hates what is in front of him, but because he loves what is behind him.' G. K. Chesterton

Besides what John had to say I have found that drilling holes in thicker plastic has one additional problem. The bit tends to really grab plastic as it cuts so make sure you have the piece well secured (clamped down) and good control of the drill. The latter in most cases (with thick plastic) means using a drill press to control the feed speed of the bit.

-- Les B, Oregon

Lexan is a good choice because it is very tough, much more so than acrylic.

-- I admit to being an adrenaline junky; fortunately, I'm very easily frightened

Polycarbonate can be cut with power tools. Acrylics will re-fuse itself on the cut lines. The heat the tool produces melts the plastic. Polycarbonate will not do this.

Just out of curiosity, how big is the unsupported span of the lexan? 3/8” is not very thick, if hanging a heavy router and a lift from the bottom of it. If the span is very big, it will sag over time, I would bet.

-- Grant Wilkinson, Ottawa ON

The plate finished dimensions will be about 11.5” square, unsupported span about 10” square. The router installed will be a Porter-Cable 1.75 HP. If it does eventually sag a bit, I’ll just replace it with something thicker.

-- PPBart

Personally I would not use Lexan. I would use a phenolic based board, like bakelite. It is stiffer and won’t sag over time. It is expensive, about $44 a sq ft. I use it on my router table.

Lexan is a good choice…

Can I use Forstner bits for the largest hole (1.5”)?

-- PPBart

Personally I would not use Lexan. I would use a phenolic based board, like bakelite…

I never thought of bakelite, but I’ll keep it in mind for the next time.

-- PPBart

Lexan is a good choice…

Can I use Forstner bits for the largest hole (1.5”)?

- PPBart

I’ve never tried it, but I don’t think a forstner bit will cut lexan. A brad point bit or a hole saw might work better. Try it out on a scrap piece.

I ve never tried it, but I don t think a forstner bit will cut lexan. A brad point bit or a hole saw might work better. Try it out on a scrap piece…

I had some scrap pieces of 1/8” Lexan, so I tested — standard twist drills up to 1/2” seemed to cut fine, nice clean holes. Then I jumped up to a 1.5” Forstner bit — it too cut just fine. I think I’ll be OK if I keep speed/pressure down.

-- PPBart

I ve never tried it, but I don t think a forstner bit will cut lexan. A brad point bit or a hole saw might work better. Try it out on a scrap piece…

I had some scrap pieces of 1/8” Lexan, so I tested — standard twist drills up to 1/2” seemed to cut fine, nice clean holes. Then I jumped up to a 1.5” Forstner bit — it too cut just fine. I think I ll be OK if I keep speed/pressure down.

- PPBart

Great! Thanks for the report on using a forstner bit on lexan. That I didn’t know.