Need help cutting rectangles - Don't laugh!

I need to cut out bunches of rectangles from 1mmx12mm up to about 5cmx15cm.

I'm cutting them out of plexiglass to make a lighted box & styrene to delineate panels & doors (This is for the shuttle bay on my NX-01)

They need to be measured pretty accurately & nice & square.

So far I've tried roughing them out on my benchtop jigsaw & trimming on the disk sander but getting bits that small accurately & squarely cut is driving me nuts!

So anybody got any hints or good inexpensive tools they want to suggest for this supposedly very basic task?

How thick are the pieces? If thin enough, I'd just use a straight edge and X-acto knife.

The styrene will be pretty thin - about 1/64" The plexi is about 1/8" The problem I'm having though is stuff slipping as I cut & not coming out quite square.

You need a laser cutter!

I said INEXPENSIVE!!! Lol! That would be my first choice though - Just don't have cash or room.

sapper36 said:

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So far I've tried roughing them out on my benchtop jigsaw & trimming on the disk sander but getting bits that small accurately & squarely cut is driving me nuts!

So anybody got any hints or good inexpensive tools they want to suggest for this supposedly very basic task?

Sounds like you already have tools that you can do this with. Invest in a combination square, draw the perfect shape onto the film on the plastic, rough out with the saw, then sand down to the line very carefully with the disc sander.

Or you could clamp the piece to a table and use a hacksaw. You can be more accurate than with a jigsaw.

Last but not least, make a fence for your jigsaw to ride against so that you get a perfectly straight cut.

Good advice. OB. I just use the band saw but you can get the same result if you invert your jigsaw in a vice. Clamp a piece of straight wood or even better aluminum to the jigsaw shield/plate at the desired width and run the piece through it. Should come out perfect every time.

one of these?
X-Acto 26232 Paper Trimmer - Walmart.com

Chop-It

I've been eyeballing this item - but don't know if it much good or not?

sapper36...awesome!

I used a dremel and thin cutting disc when I was cutting plexi for a clear box to encase wiring and electronics. You'll still need to sand the edges to remove flash when you're done. And it might be a bit tedious if you're doing a lot of rectangles that require very precise work

how many do you need?

sapper36 said:

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Chop-It

I've been eyeballing this item - but don't know if it much good or not?

I have a similar tool called "The Chopper". Maybe I need a thicker blade, maybe my stock is too thick, maybe I am pressing too hard, but I find my chopper drifts. So my cuts are not a straight 90 degrees to the cutting surface.

Orange_Blend said:

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Make a fence for your jigsaw to ride against so that you get a perfectly straight cut.

^^ That's how I've cut small pieces out (plywood, perspex, etc) in the past

You can use the edge of a spirit level (if you have one that isn't dented) or a piece of aluminium or steel (if you have access to either).

In my experience, an X-Acto mitre box and a razor saw can work wonders. The box keeps the long ends nice and square and a slot for the saw blade to pass through does the job if one desires to work slowly (it can be tedious though).

Are you making sure to mark your plexi so you know where to make the cuts? If your guide lines are marked clearly, usually the cuts go pretty well since your eye has something to focus on. The marks can always be removed after the cut is made.

It would be nice to know where in Australia I could find a "Chop-it" or "The Chopper"

Hi Sapper, long time no see!

for straight cuts on thin to medium styrene I just use a guillotine papercutter, they are great for getting 90° angles. I am not sure if a paper trimmer could be used to score and snap a thicker piece, but it would be worth checking out. Otherwise like OrangeBlend mentioned I just clamp down a straight edge and cut with whatever is at hand.

moffeaton said:

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You need a laser cutter!

sapper36 said:

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I said INEXPENSIVE!!! Lol! That would be my first choice though - Just don't have cash or room.

What about taking your work to one? I have had heaps of jobs done by a small firm [owner is semi retired] that prefers the small "one offs" I send him Vs the larger contracts. He supplies the material and on average, my jobs cost about $50~$100.

Junk Pilot said:

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It would be nice to know where in Australia I could find a "Chop-it" or "The Chopper"

Here is the company info:

NWSL - NorthWest Short Line

Scroll down to find items.

I got one of the Micromark Choppers- best twenty bucks I ever spent. It can churn out piles of accurately sized styrene bits in minutes. Totally relieves the sort of job that used to take hours and had a high "dud" factor. Drawback: the razor blade will track slightly (parallel to the swing arm) if the material you are cutting is thicker than 1/8th of a inch. Otherwise its a great little tool.

this looks like a good tool , I need to get one !

The Duplicutter II - NorthWest Short Line

I have the Duplicutter II and it's not too bad. i want to get the chopper and a few others for fine detail stuff.

I've used a local acrylic shop and for a 24" x 24" sheet of acrylic was $20 USD to cut same piece into 1" x 3" pieces. An option

Get this: Sand-It It will help you square everything up perfect.