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Plugging holes in plexiglass
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Author:  bcombs510 [ Thu May 28, 2020 6:55 pm ]
Post subject:  Plugging holes in plexiglass
Hello,

I have the SM saddle routing jig and I want to fit the plex template to a plunge base for the DeWalt 611. The existing holes are just off from the alignment for the plunge base. I’d like to plug and redrill the holes.

Any tips on how I can do this? Can I simply use epoxy and will it hold if just putting a puddle of it in the hole while it’s sitting on wax paper or similar? Or will that just pop back out as soon as I go to drill it?

Ideas are appreciated.

Brad


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Author:  Ken Lewis [ Thu May 28, 2020 8:31 pm ]
Post subject:  Re: Plugging holes in plexiglass
I'm doubtful about filling the holes in plexi. What if you rotated the alignment by 45 deg. and
drilled new ones??
Author:  Chris Pile [ Thu May 28, 2020 8:35 pm ]
Post subject:  Re: Plugging holes in plexiglass
Make it new....
Author:  DennisK [ Thu May 28, 2020 9:26 pm ]
Post subject:  Re: Plugging holes in plexiglass
If you want to give it a shot, rough up the surface, wipe with alcohol or acetone to degrease, and mix some kind of powder (e.g. baking soda) with the epoxy to boost the strength. I've done that on 3D printed PLA and resulted in strong fixes. But plexiglass may be more resistant to adhesion.
Author:  Clay S. [ Fri May 29, 2020 12:25 am ]
Post subject:  Re: Plugging holes in plexiglass
You can use acetone to solvent weld plexiglass plugs into the existing plexiglass template. They also make special glues for it, but acetone works O.K. and is a component in most lacquer thinners (which may also work - test on scrap).
Author:  bcombs510 [ Fri May 29, 2020 2:10 pm ]
Post subject:  Plugging holes in plexiglass
Thanks for all the replies. Below is what I ended up with. I took a closer look at the plate from SM and the piece that slides in the channel was only attached with two pins. So I popped the pins out and glued it to the plate for the plunge base. I also drilled and tapped two 10-24 holes and screwed the plates together. Just in case. :) It’s ready to ride!

Here is the smaller plate that rides in the channel.

Image

Center it up and glue it.

Image

Image

Added some screws.

Image

Image

In case anyone wants to upgrade. :)

Brad


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Author:  James Orr [ Fri May 29, 2020 5:36 pm ]
Post subject:  Re: Plugging holes in plexiglass
I have the same trimmer setup, the same jig, and the same desire to upgrade. Thanks, Brad!


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Author:  bcombs510 [ Fri May 29, 2020 6:09 pm ]
Post subject:  Plugging holes in plexiglass
James Orr wrote:
I have the same trimmer setup, the same jig, and the same desire to upgrade. Thanks, Brad!


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Cool, glad it’s useful. A note - think about the clamping you like to use and the ears of the plunge base and orient accordingly. If you like to use cam clamps position the base so that the ears won’t be blocked by the cam levers.

Hope that makes sense. :)

Edit: What I mean is glue the piece from the SM base so that the ears of your plunge base are out of the way of your clamp setup.

Brad


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Author:  James Orr [ Sat May 30, 2020 2:09 am ]
Post subject:  Re: Plugging holes in plexiglass
Good call. I like the way you oriented it.


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