ABS plastic door panels- question

[S.osolit13]

saw a cool and great idea someone did to there z, they used abs plastic to make door panels out of so i thought id give it a shot. But i purchased the panels and asked the guy if he could cut them to the correct shape, he said he could but it would be 250$ now im no plastic cutter but that seams outrageous to me so me question is. What is the best way to cut ABS plastic? or if anyone's done this before what steps they took? i can add pics if needed

 

thanks 

[Laecaon]

ABS is very easy to cut. Hot knife, Jigsaw, sawsall, endmill....  It doesnt crack easily and is very forgiving.

 

 

I cut all of my ABS door panels with a Jigsaw.

[kelowg]

With jig saw, just make slightly larger so u can sand down to smooth edge. If thin enough,u can even cut with heavy duty scrissors.

[thisismatt]

I would probably cut out a template from luan, mdf, masonite, whatever, then use a router and a template bit to cut the ABS nice and clean.  Then again, I do finish carpentry so I already have all the tools...

[Laecaon]

Acetone will also smooth ABS a bit (chemically melts it)

[S.osolit13]

i heard using a jigsaw and other thing like it well melt the plastic while cutting it though?

[Laecaon]

Only at the cut, wood blade, and keep the blade cool. Keep a bucket of ice near and cool the blade, helps a ton.

[datzenmike]

Avoid anything that abrades to cut. These tools will generate friction and melt their way through the plastic.

 

Jig-saw

If the cutting teeth on a jig-saw are too widely spaced (course) it will grab too much and can chip or start a crack. Too fine will not clear the teeth of cut plastic and it will just grind away and heat up enough to melt and then you really are in trouble. Try different tooth count blades on a piece of scrap first to get the best cut. The plastic must be securely held down so it doesn't begin osculating from the blade cutting. Masking tape the surface and draw lines on it to keep the cut straighter. Take your time to prevent heat

 

Skill-saw

For long straight cuts use a skillsaw with the blade in backwards. (Or a 200 tooth specialty blade for plastic)

This prevents the teeth grabbing on the down cut and basically 'grinds' it's way along but works well enough if you take your time and is faster than a jig-saw. 

[S.osolit13]

I was thinking a dremal to cut it and just cut abit further out then I need to and sand it but i just don't wanna melt it

[datzenmike]

If you have a straight edge to guide you otherwise a dremel wanders. Also the high speed will heat up.

[S.osolit13]

Yea I have a couple tools I'm gonna try tomorrow see what one does the job the best! Thank you guys!

[k-wad]

Hi There,

 

New guy with a question.

I would like to make some ABS door/kick panels for my Roadster (a 1968 1600), but, don't know where to purchase the ABS sheets.

Any suggestions on places that sell the ABS sheets at a decent price?

 

Thanks,

[S.osolit13]

i just searched up a plastic store on google and one popped up but im on van island and i got two sheets 25 tall by 40 wide and it came out to 92$ after taxes abs is pretty popular i guess so it should be easy to find and btw i got 1/8 thick sheets for my door panels

[DanielC]

In Ontario, Try www.tapplastics.com.

I believe they will also ship.

[spottedog]

Hi There,

 

New guy with a question.

I would like to make some ABS door/kick panels for my Roadster (a 1968 1600), but, don't know where to purchase the ABS sheets.

Any suggestions on places that sell the ABS sheets at a decent price?

 

Thanks,

Tap Plastics  in San Jose, California    Good people great service.

[k-wad]

Spottedog,

 

Thanks for the heads up. Exactly what I was looking for. Prices seem good, too.