How to Make a Hole in Plexiglas

Plexiglas porthole

One of the characteristics of Plexiglas is that it is impact resistant. While the reason for needing to drill a hole in such material may differ, the procedure to do so remains the same. It is essential that a number of precautions be taken to preserve the Plexiglas sheet as the material is brittle.

Things You'll Need

• Power drill
• Water bottle with spray head
• Drill bit(s) for use with Plexiglas
• Wooden board (or workbench)
• Padded clamps

Instructions

1. Measure precisely and mark the Plexiglas where the holes need to be drilled.

2. Place the Plexiglas flat on wooden board or workbench where it is completely supported to relieve the stress of drilling.

3. Secure the Plexiglas with a set of clamps to the board to prevent it from moving while you are drilling.

4. Select the proper drill bit for your hole diameter. It is essential that you select a slightly larger drill bit if the hole is for a screw as Plexiglas expands and contracts with atmospheric pressure, humidity and temperature. If there is no room for expansion or contraction, then the Plexiglas will crack.

5. Prepare a water bottle with a spray head. While drilling, the water can be sprayed on the Plexiglas in order to keep it cool and lubricated for the drill bit.

6. Drill a pilot hole (a small test hole) in order to relieve some of the stress that a larger drill bit will cause.

7. Select slightly larger drill bit sizes and repeat the previous step increasing in diameter slightly each time until the hole is the desired diameter.

Tips & Warnings

• Two alternative methods for drilling a hole in Plexiglas involve using a step drill bit instead of drilling consecutively larger diameter holes or by using a soldering iron to slowly and carefully melt a hole through the Plexiglas.

• Select a drill bit that is designed for using with Plexiglas. Regular drill bits are designed to bite the material they drill, and this sort of pressure will cause chips in Plexiglas. While drilling, use a steady gentle pressure to ensure that the Plexiglas does not crack or chip.

References

• Drilling holes in Plexiglas
• R&H 1/8-inch Plexiglass Acrylic & Lexan Drill Bit
• Cutting Plexiglass