Snapped my acrylic side panel while drilling a fan hole - rookie move

So I was trying to add a 120mm fan mount to the side of my scratch-built case last Sunday. I had the layout all marked out with tape and I was using a step bit to get a clean hole. About halfway through drilling the second hole, the acrylic just cracked straight across. I felt like such a fool because I forgot to back the panel with a wooden board to stop it from flexing. Now I have to cut a whole new piece of 3mm acrylic from the hardware store which will run me about $15. Any tips on drilling plexiglass without it shattering again?

2 comments

2 Comments

coleman.jade2d ago

Drill your starter hole MUCH bigger than you think you need with a regular bit first, then switch to a step bit once you have that pilot hole in place. Back the WHOLE panel with a sacrificial piece of MDF or plywood clamped together so the acrylic has zero room to flex or vibrate. Also run your drill at its lowest speed and use a little bit of dish soap mixed with water as lubricant to keep the plastic from overheating and getting brittle.

rowank692d ago

Honestly bro $15 for a new piece of 3mm acrylic is not the end of the world. You didn't snap a tempered glass panel that costs $80 and leaves glass dust everywhere. Just buy the new sheet and move on, we've all cracked something dumb before.