If you are new to the world of construction, you want to insert plexiglass windows into a structure, or you need to make plexiglass dividers to deal with a pandemic, you will first need to know how to cut the material.
One of the best tools that you can use to cut plexiglass is a jigsaw, and right now we will teach you how to do just that.
Is a Jigsaw the Best Tool for Cutting Plexiglass?
Seeing as there are so many different types of saws and cutting utensils out there, you might be wondering if a jigsaw is in fact the best tool for the job. The fact here is that yes, for most applications, the jigsaw is the best type of saw to be used to cut plexiglass.
This is especially true if you are cutting anything but a straight line.
That said, there are other tools that can be used for this task as well.
Some of the other options here include a basic circular saw, a table saw, or even a utility knife too. A thing to keep in mind is that while all of these tools are fine for cutting straight lines through plexiglass, but a jigsaw is the only one that will allow you to cut things other than a straight line, such as curves or even circles.
Finally, if you are cutting a very thin piece of plexiglass, you don’t really need a power saw at all. The easiest way to cut a thin sheet of plexiglass is by using a utility knife or special glass scoring tools. All you really need to do is to score a straight line where you want to make the cut, clamp the sheet of Plexiglas down to a worktable, and then quite literally snap it off.
For anything substantial in thickness, you will want to use a power saw, such as a jigsaw, though.
How to Cut Plexiglass with a Jigsaw
Cutting plexiglass with a jigsaw may sound like a super simple task, and in all reality, it’s not that hard. However, the material, although much more durable than regular glass, can still break, especially if you saw it the wrong way.
Therefore, in order to cut plexiglass with a jigsaw without having it shatter on you, follow the steps as outlined below for the best results. Keep in mind that there we will cover how to cut both straight lines and circles out of plexiglass with your jigsaw.
Step 1: Prepare the Jigsaw
The first step that you need to take here is to prepare your jigsaw for plexiglass cutting. The reason for this is because not all jigsaw blades are ideal for cutting this material, certainly not your basic wood cutting jigsaw blade.
Something like a 10 TPI carbide blade should do fine. Any blade designed for plastic cutting should also work fine for cutting plexiglass. Make sure to insert and secure the proper blade into your jigsaw so that it does not come loose during operation.
The blade should not have more than 10 teeth per inch, and no less.
Step 2: Mount the Plexiglass
The next step to be taken to cut your plexiglass sheet with a jigsaw is to mount the plexiglass sheet on a sawhorse. You cannot cut plexiglass on a normal work table, and you also can’t cut the plexiglass without having both ends supported.
Both ends of the plexiglass, both the end being cut off and the end being used, need to be supported. Else, when you make your cut, the plexiglass may snap off due to its weight.
Therefore, get a sawhorse, some basic clamps, and secure the plexiglass to both sides.
This is especially required if you plan on cutting a circle into the plexiglass, instead of just cutting off a straight line.
Step 3: Mark the Cut on the Plexiglass
Next, you need to mark the line or circle that you are going to cut out of the plexiglass with your jigsaw. To do this, always be sure to use a ruler, a compass, or any other appropriate measuring tool. Always measure twice before making any cut, because once you make a cut, you won’t be able to reverse it.
A normal pen or pencil won’t work on plexiglass, so you will need to use a grease pen. Once you have made your cutting line with the grease pen, cover that line with some painter’s tape or masking take, and then re-draw the line over the tape. The tape is used to prevent the plexiglass from splitting or cracking while making the cut.
Step 4: Prepare the Plexiglass (If Cutting Plunge Cuts)
In case you are just cutting a straight into the plexiglass, not a circle, then you can skip this step.
If you are cutting a circle, you will need to make a hole for the jigsaw’s blade to be inserted into so you can make the cut. In this is the case, use a drill with a special bit designed for plexiglass, and drill a hole large enough for the blade to fit through. Be sure to make this drill hole on the inside of the circle.
However, if the circle is what you are planning to use, you can start cutting from the outside like you normally would
Step 5: Make the Cut
Now it is time to make the cut.
If you are sawing out a circle, insert the blade of the jigsaw through the hole drilled in the previous step, get the blade up to full speed, and push the jigsaw along the line to make the cut. If you are just splitting a piece of plexiglass, just get the saw up to full speed and follow the line to make a cut.
Always be sure to keep your hands away from the blade, and if need be, support the piece being cut off so that it does not fall to the ground as you make the cut.
Step 6: Sanding and Buffing
You will most likely end up with some burrs and rough edges, so you will want to start with 120 or 180 grit waterproof sandpaper and a sanding block to sand down the edges.
Once they start getting smooth, switch to 600 grit sandpaper for final sanding and buffing.
Mistakes to Avoid, Tips, & Tricks
To help make your life a little easier, let’s talk about some tips and tricks to help make cutting plexiglass with a jigsaw as easy and as safe as possible:
- Always be sure to use a blade designed for cutting plastic or plexiglass, one with a relatively high tooth per inch count. A normal wood cutting jigsaw blade will not work for this application.
- Plexiglass can get quite hot while being sawed. If you are worried about excess heat, or you start seeing smoke, pouring a small amount of cool water over the blade and the cutting area will help to keep things cool.
- Always wear safety goggles when using a power saw such as a jigsaw, always tie back long hair, and never wear loose clothing that can get caught in the blade.
- Never saw plexiglass with one end hanging out in the open. You need both ends to be supported, or else the plexiglass may snap or shatter due to its weight, particularly as you get further along in the cut.
- Never force the blade along too fast. Moving too fast may cause damage to the plexiglass.
Summary
The bottom line is that it is totally possible to cut plexiglass with a jigsaw, and if you follow our guide, as well as our tips as outlined here today, you should have no problems doing so. It all comes down to having the right blade, the right tool, and the right process.
If you are interested in different methods, read my article about the best ways to cut plexiglass.