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How to Build a Plexiglas Case

You can use Plexiglas--a clear thermoplastic--to build a unique case for storing items including CDs, dolls and other collectibles. Plexiglas can be difficult to work with because it's so brittle. But with a little know-how about how to handle it, cut it and put it together, you can have an attractive, well-built Plexiglas case in no time.

Things You'll Need

Marker Yardstick Variable-speed band saw with a fine-toothed blade Glue designed for bonding Plexiglas

Instructions

- 1
  Plan your Plexiglas case in detail. Decide on its design. For example, how many sides will it have? Will it have shelves? If so, how far apart will they need to be? You'll also need to determine the dimensions of your Plexiglas case. Determine how many sheets of Plexiglas you'll need for this project, and how thick it should be. The thicker the material, the more durable. It's also easier to handle and fabricate. A 1/4-inch thickness usually works well. The largest sheets you can buy are 4 feet wide and 8 feet long. Plexiglas is available at the hardware or home supply store.
- 2
  Leave the protective paper on both sides of the Plexiglas right now. Take care not to bend it, as it can crack or break. Measure and mark out the pieces you'll need to assemble your case.
- 3
  Use a variable-speed band saw with a fine-toothed blade to cut the pieces out of the Plexiglas. Use care when cutting this material. Cut it too fast, and it can crack or break. Cut it too slow, and the heat from the metal blade can melt the Plexiglas. It's best to cut rather slowly, inches at a time.
- 4
  Remove the protective paper on the Plexiglas. Then, carefully sand the cut edges of the pieces to remove the burrs and rough edges.
- 5
  Follow your plan and glue the pieces of your Plexiglas case together. Allow the glue to dry undisturbed according to the manufacturer's directions.

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