Cutting ¾” LEXAN® sheet with circular saw?

[Bruce Page]

A friend needs to cut some ¾” thick, 4’X8’ lexan sheet into 12” X8’ strips and asked me for some tips. Having never done anything quite like this I thought someone here might have some experience/suggestions that I could give him.

He needs a fairly clean edge & doesn’t want to use a jig/reciprocating saw.

Is it even doable?

[Doug Shepard]

I did this 1/2" thick stuff on the TS with an 80-tooth Freud blade a while back for the door on my router extension. It cut well. No ragged or rough edges.

http://www.sawmillcreek.org/attachment.php?attachmentid=133021&d=1258505454

[Bruce Page]

Thanks Doug. My friend lives in Phoenix and doesn’t have access to a TC or BS. I’ve cut ½” on my TS, cuts like bahutter.

[Chris Damm]

A table saw with an 80 tooth planer blade would be my 1st choice. He isn't going to get a smooth edge with a circular saw. He might be able to cut them a little oversize and sand the edges but that will take more material and that stuff is expensive.

[Gene Howe]

I've used a torch to "flame" the edge on thinner 1/4"-1/2" pieces. Works better than sanding and leaves a clear finish.

[Roger Savatteri]

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When flaming i've found that it is best to use wet/dry sandpaper beforehand to prep the edge working from 220 to 400 grit.

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