Thread: Help sanding 2" holesaw scratches on 12mm acrylic/plexi

Originally Posted by barrysumpter

I've cut a 2" hole in 12mm 5" square acrylic.

Sanding and buffing the outside square edges of the acrylic was easy enough.
Using a random orbital sander and a buffing wheel on a bench grinder.


I'd like to sand and buff the inside of the 2" hole.

I've fitted a rotary drum sander to my drill press.

But regrettably make very little progress.

Any suggestions?

Thanks in advance.

Sent from my iPhone using Tapatalk

As usual I find a solution 5 mins after posting:

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Fingers hurting after the first one.
Any other suggestions are welcome.

Yeah I was gonna say just make a small buffing thing to go in the drill

If required, to generate a clear transparent fine, remove scratches with successive grits up to 800 grit wet and dry and then use a hot flame/air finish.
This is the integral BMH on my OH TS guard - routed and then sanded and flame finished.

I used a MAPP gas torch but a hot air gun can be used.
You will need to practice with time and distance from flame otherwise you can make a real mess.
If bubbles start appearing in the acrylic you have gone too far.

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Thanks heaps.

I did consider flame polishing.

It's a developed art. More error in trial and error.

The cost and risk of damaging a work piece was off-putting.

The sanding and buffing would take a lot longer but without loss of investment.

Sanding thru the range then just the cotton buffer and was as last step.
Came up very clear.

Just a thought but try acetone on a lint free cloth. Just on the hole and not on the surface.

OK building another.

Is there a way to cut the hole without leaving teeth marks/scratches?
Or maybe less teeth marks/scratches?

A carbide tipped holesaw might cut cleaner than a normal one.

Tried the hole saw again with a bit of dish washing liquid.
Will have a good look tomorrow.