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8.2.2 HOW TO DRILL PLASTIC
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Wood drill bits can be used to cut plastics, but bits designed for glass drilling yield better, safer results. If you use wood bits, you should modify them by blunting the tip slightly (otherwise the tip may crack the plastic when it exits the other side). Continue the flute from the cutting lip all the way to the end of the bit (see Fig. 8-1). Blunting the tip of the bit isn t hard
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Cutting lip Standard bit Modified bit
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FIGURE 8-1 Suggested modifications for drill bits used with plastic. The end is blunted and the flutes are extended to the end of the cutting tip.
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PLASTIC PLATFORMS
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to do, but grinding the flute is a difficult proposition. The best idea is to invest in a few glass or plastic bits, which are already engineered for drilling plastic. Drilling with a power drill provides the best results. The drill should have a variable speed control. Reduce the speed of the drill to about 500 to 1000 r/min when using twist bits, and to about 1000 to 2000 r/min when using spade bits. When drilling, always back the plastic with a wooden block. Without the block, the plastic is almost guaranteed to crack. When using spade bits or brad-point bits, drill partially through from one side, then complete the hole by drilling from the other side. As with cutting, don t force the hole and always use sharp bits. Too much friction causes the plastic to melt. To make holes larger than 1 4 in you should first drill a smaller, pilot hole. If the hole is large, over 1 4 in in diameter, start with a small drill and work your way up several steps. You should practice drilling on a piece of scrap material until you get the technique right.
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8.2.3 HOW TO BEND AND FORM PLASTIC
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Most rigid and semirigid plastics can be formed by applying low localized heat. A sure way to bend sheet plastic is to use a strip heater. These are available ready-made at some hardware and plastics supply houses, or you can build your own. A narrow element in the heater applies a regulated amount of heat to the plastic. When the plastic is soft enough, you can bend it into just about any angle you want. There are two important points to remember when using a strip heater. First, be sure that the plastic is pliable before you try to bend it. Otherwise, you may break it or cause excessive stress at the joint (a stressed joint will look cracked or crazed). Second, bend the plastic past the angle that you want. The plastic will relax a bit when it cools off, so you must anticipate this. Knowing how much to overbend will come with experience, and it will vary depending on the type of plastic and the size of the piece you re working with. You can mold thinner sheet plastic around shapes by first heating it up with a hair dryer or heat gun, then using your fingers to form the plastic. Be careful that you don t heat up the plastic too much. You don t want it to melt, just conform to the underlying shape. You can soften an entire sheet or piece by placing it into an oven for 10 or so minutes (remove the protective plastic before baking). Set the thermostat to 300 F and be sure to leave the door slightly ajar so any fumes released during the heating can escape. Ventilate the kitchen and avoid breathing the fumes, as they can be noxious. All plastics release gases when they heat up, but the fumes can be downright toxic when the plastic actually ignites. Therefore, avoid heating the plastic so much that it burns. Dripping, molten plastic can also seriously burn you if it drops on your skin.
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