Best way to replicate clear plastic?

[brad808]

So I have a broken plastic on one of my games that I was going to try and replicate. The plastic is a clear one so it should be a matter of just simply cutting a new one to size. My question is what is going to be the best way to go about this? In the past when I've needed to cut plexi I've always just used my router and a flush trim bit to match it up with things like control panels for vids etc. Something tells me that won't work to well in this case due how thin the original is so I'm searching for other ideas.

 

[spiroagnew]

I've used a sheet of Lexan and a Dremel tool...oh, and a steady hand. The Lexan resists chipping and cracking...the Dremel cuts through it like butter.

 

[DRANO]

I prefer the CNC myself

Dremel will work well. Sand the edges smooth and then flame polish them with a small torch. I like the cheap butane BBQ lighters for this.

 

[brad808]

The dremel sounds like a good idea. Thanks for the tip guys. I have a small butane torch as well so maybe I'll give this a try tonight.

Sent from my Nexus 4

 

[BMHouze]

I had the maintenance guys at work cut me a new clear piece for my Atlantis for the drop target bank. I only had to countersink the holes due to the thickness. free is free after all.
The maintenance department calls this 'government work'....

 

[Luckydogg420]

If you don't have a dremmel, and a router is the only option. Then I'd make a templates of the original plastic outta thicker material like good 3/8" plywood, and then use the flush trim bit like you said. Sand edges, polish and your done.

 

[DRANO]

I have a small butane torch as well so maybe I'll give this a try tonight.

Sent from my Nexus 4

Just a few seconds and keep the torch moving or you'll bubble the plastic. Practice on some scrap first.
Flaming will give it a nice clean glossy factory edge.

I made these custom WH2O inlane plastics a while back... but I did have the blanks cut on our CNC first.

 

[spiroagnew]

I made these custom WH2O inlane plastics a while back... but I did have the blanks cut on our CNC first.

Still waiting for one of these, friend!

 

[DRANO]

Ha!
I ran out pretty quick. I may revisit the mod again one day.
Just have too much on the go and don't feel like using up another CNC favour just yet

 

[brad808]

Thanks again guys. The dremel worked out well.

Looks much better than the old beat up yellow one.

 

[tim.sanderson]

That looks fantastic. Good job!