Are you looking for a way to cut Perspex but don’t have access to a circular saw or power saw?
Fear not, because an angle grinder can do the job just as well!
While most people associate angle grinders with cutting metal, they can also be used to cut plastic, including Perspex.
However, there are a few things to keep in mind when using an angle grinder for this purpose.
In this article, we’ll guide you through the process of cutting Perspex with an angle grinder, including the type of blade to use and tips for avoiding melting or fusing the plastic.
So grab your angle grinder and let’s get started!
How To Cut Perspex With Angle Grinder
Step 1: Choose the Right Blade
The first thing you need to do is choose the right blade for cutting Perspex. For this task, you’ll want to use a diamond blade with a fine tooth count. This type of blade is specifically designed for cutting through hard plastics like Perspex.
Step 2: Mark Your Cut Line
Using a marker or pencil, mark the line where you want to cut the Perspex. Make sure the line is straight and even, as this will help you achieve a clean cut.
Step 3: Secure the Perspex
Before you start cutting, make sure the Perspex is securely clamped or held in place. This will prevent it from moving around while you’re cutting and help you achieve a straight cut.
Step 4: Set Your Angle Grinder
Set your angle grinder to a low speed setting. This will help prevent the blade from melting or fusing the plastic as you cut.
Step 5: Begin Cutting
With your angle grinder and diamond blade ready, begin cutting along the marked line. Take your time and use a steady hand to ensure a clean and even cut.
Step 6: Clean Up the Edges
After you’ve finished cutting, use sandpaper or a file to smooth out any rough edges or burrs on the Perspex. This will give it a clean and professional look.
Choosing The Right Blade For Cutting Perspex
Choosing the right blade for cutting Perspex is crucial to achieving a clean and precise cut. The type of blade you use will depend on the hardness of the Perspex you’re cutting. For hard plastics like Perspex, a diamond blade with a fine tooth count is recommended. This type of blade is designed to cut through hard plastics without causing cracks or breaks in the material.
It’s important to note that using the wrong blade can cause irreversible damage to your Perspex, and may even cause injury. For example, using a blade that is too coarse or dull can cause the Perspex to crack or break during cutting. On the other hand, using a blade that is too fine may take longer to cut through the material, and may cause overheating of the blade.
When choosing a blade for cutting Perspex with an angle grinder, it’s important to consider the thickness of the material as well. Thicker Perspex may require a thicker blade with a larger diameter to ensure a clean and precise cut.
Preparing Your Workspace For Cutting Perspex
Before you start cutting Perspex with an angle grinder, it’s important to prepare your workspace properly. Follow these steps to ensure a safe and efficient cutting process:
Step 1: Choose a well-ventilated area
Perspex can produce fumes when cut, so it’s important to work in a well-ventilated area. Open windows and doors and use a fan or ventilation system if possible.
Step 2: Clear the workspace
Clear the workspace of any clutter or debris that could get in the way while you’re cutting. Make sure there is enough space for you to move around comfortably.
Step 3: Choose a suitable work surface
Choose a work surface that is sturdy and flat. A table made of concrete, metal, or wood is ideal. Avoid using a table made of plastic, glass, or paper as the solvent-based glue being used in the project may cause the Perspex to attach to the surface, damaging both the material and the table.
Step 4: Protect your work surface
To protect your work surface from scratches or damage, cover it with a soft cloth or mat. This will also help prevent the Perspex from slipping while you’re cutting.
Step 5: Wear protective gear
Wear appropriate protective gear such as safety glasses, gloves, and a dust mask. This will help protect you from any debris or fumes produced during the cutting process.
By following these steps, you can ensure that your workspace is safe and ready for cutting Perspex with an angle grinder.
Measuring And Marking The Perspex For Cutting
Before cutting Perspex with an angle grinder, it is crucial to measure and mark the material accurately. This will ensure that you achieve the desired size and shape for your project. To do this, you’ll need a tape measure, a marker or pencil, and a straight edge.
Start by measuring the length and width of the Perspex sheet using a tape measure. Be sure to make precise measurements and double-check your work to avoid any mistakes. Once you have your measurements, use a straight edge to mark the cut line on the Perspex. Make sure the line is straight and even, as this will help you achieve a clean cut.
It’s important to note that markings on tape measures can sometimes differ, so it’s recommended to always use the same tape measure during the project you are working on. To mark the correct distance, use a grease pencil or marker and place short dashes along the cut line. Once the short dashes are marked, connect them with a ruler and mark a line along the path.
When marking the Perspex, it’s essential to be gentle to avoid scratching or damaging the surface. Additionally, make sure that the Perspex is securely clamped or held in place before you start cutting. This will prevent it from moving around while you’re cutting and help you achieve a straight cut.
By measuring and marking your Perspex accurately, you’ll be able to achieve precise cuts with your angle grinder. This will result in a professional-looking finished product that meets your exact specifications.
Tips For Avoiding Melting Or Fusing The Perspex
When cutting Perspex with an angle grinder, it’s important to take precautions to avoid melting or fusing the plastic. Here are some tips to keep in mind:
1. Use a low speed setting: As mentioned in Step 4 above, setting your angle grinder to a low speed will help prevent the blade from generating too much heat and melting the Perspex.
2. Keep the blade cool: To further prevent melting, you can also use a cooling agent like water or oil to lubricate the blade as you cut. This will help dissipate heat and keep the blade from overheating.
3. Don’t apply too much pressure: Applying too much pressure while cutting can also generate heat and cause the Perspex to melt or fuse. Instead, let the blade do the work and use a light touch to guide it along the cut line.
4. Avoid stopping and starting: Stopping and starting the angle grinder can create friction and heat, which can melt or fuse the Perspex. Try to make continuous cuts without pausing if possible.
By following these tips, you can achieve a clean and precise cut on your Perspex without damaging or fusing the plastic.
Finishing And Cleaning Up After Cutting Perspex With An Angle Grinder
Once you’ve finished cutting your Perspex with an angle grinder, it’s important to take the time to clean up and finish the edges. This will ensure that the cut looks professional and is safe to handle.
Step 1: Sand the Edges
Start by using sandpaper to smooth out any rough or jagged edges on the Perspex. Begin with a coarse grit sandpaper, such as 120 or 180-grit, and work your way up to a finer grit, such as 600-grit. Use a sanding block to keep the sandpaper flat against the Perspex and to ensure an even finish.
Step 2: Buff the Edges
Once you’ve sanded the edges, it’s time to buff them to a high shine. To do this, you’ll need an electric drill outfitted with a buffing pad and a plastic polishing compound. Apply a small amount of the polishing compound to the buffing pad and carefully buff the edges of the Perspex until they’re smooth and shiny.
Step 3: Clean Up
After you’ve finished sanding and buffing the edges, it’s important to clean up any debris or dust that may have accumulated during the cutting process. Use a soft cloth or brush to wipe down the Perspex and remove any remaining particles.
By following these simple steps, you can achieve a clean and professional-looking cut on your Perspex using an angle grinder. Remember to take your time and use caution when working with power tools, and always wear appropriate safety gear such as goggles and gloves.