hey i'm gonna build a case from lexan/polycarbonate, and I know that it's very shatter resistant, but is 1/8 of an inch thick enough for a case made of this? I'm not making it tower style so it's not going to have to support loads very high up. the 1/8 inch material is MUCH cheaper than the 1/4 inch, i am planning on buying my stuff from this site. thanks EDIT: Oh i forgot to ask, can you score lexan to cut it or will i have to whip out my hacksaw or jigsaw
yes you can score lexan to cut it but it requires strength, and after it breaks alot of filing down to get it smooth. 1/8 lexan is to thin for a computer case, 1/4 is perfect for a computer case.
I agree. Most aftermarket acrylic cases are 1/4". I used 1/8" for my front panel covers. I did not try but they say lexan is harder to work with than acrylic. Also I tried the score/break deal and was not happy. A hack-saw works great, and you can get very clean cuts. http://server6.uploadit.org/files/jeffrey9-IMG_0301.jpg MS
Tutorial I wrote on this subject The optimum thickness will depend on the size of enclosure you're trying to build. 1/4" will flex far less than 1/8" and will provide a more rigid structure. If you want to get 1/4" at a next-to-nothing price, search your local phone book for plastics shops. Just call a few and ask if they sell any scrap polycarbonate. If they do you can get whatever you need at $2 per pound (sometimes less). The Lexan will be clearly marked (as LEXAN, GE, Rhinex, or Tuffex) and covered in white static film. I do not recommend trying to score and snap polycarbonate. To cut polycarbonate I recommend using a variable speed jigsaw with a smooth-cut metal blade. Use medium speed and you shouldn't have any problems with melting. Ideally a table saw is the best tool for the job.
