My router

[Cold Fusion]

Nice arms. The holes are the hardest part because they can't be done on a cnc router.

Lexan is fairly easy to cut by hand with a band saw, jig saw, ect. I have always contracted out my work for the chassis so I couldn't tell you about the cnc process.

[DJ Morrow]

I never cease to be amazed at the diverse interests and talents around this place.

[Hobbiest]

Great job Kong! Hopefully I will get there soon. I have built three machines now, but my former partners did the running. I am a hot rodder by history, and a fabricator by habit, and can't wait to get something cut out! Just gotta make the money to do a project for myself. Btw...WD-40 rubbed on to bare steel with a scotch brite pad or rag will keep it from rusting. You have to do it about once a week for a car that sees the outside a lot, but I don't know about inside only stuff. Old hot rod trick.
Cheers

[xairflyer]

I work a lot with lexan sheet and it is one of my reasons to build a large 8x4 machine down the road.

The jigsaw is my preferred method of cutting, the pitch of the blade is the most important you want 2 - 2.5mm of pitch (around 3/32") with a new blade you will be left with a perfect finish.

Lexan can also be scored and snapped like glass, so long as it is not too thick.

I also plane the edges with a wood plane, works great.

[Konrad]

Excuse me for butting in.
I must say, to all of you wood & steel Router Guys, you are doing such a nice Job in those CNC Routers and posting all these pics.This is Interesting Stuff!
I'm a machinist, and woodworking I have done a little bit in the past.
Some days, I would like to mount a router on my mill and do some steel carving.

Kong: it looks like that Makita of yours is the way to go.I can't stand Noise!
I only got 4000 RPM on my MAHO CNC mill.

Konrad

[Cold Fusion]

Kong, do you think that cutting 1/4 aluminum would be too much of a chore on a regular basis if my router were at least as solid as yours?

Sorry to bring up an old thread but you're one of the only people who cuts aluminum with their routers.

[kong]

I don't think cutting 1/4" ali woul dbe a problem, but that will depend on the type of cutting you are thinking of. Now, if you are making a flat chassis for an RC-car, it should be ok, but if you want to create a nice 3d surface in that 1/4" ali, I wuold forget it!
So yeah, 2.5D will be fine, but would really strain the machine for constant 3D cuts.
Somewhere in the diy router section is another router, built especially for aluminium, but I have no idea who made it.....perhaps Steve someone? It uses a "C" section ali for the cross members, and looks extra strong. It is worth hunting for.

[Cold Fusion]

Yeah, it's all flat 2d stuff.