Does anyone know the best tool/way to cut holes for 1/2" ID tubing that won't butcher acrylic?

And what is the exact size to do that? I see people who have done this and put lining around the holes too, or rubber caps or whatever they're called, how is that done?

Help much appreciated. Thanks!

ok the way i do it is .
calculate the O.d. (outer diameter) needed.
most 1/2 I.D. tube is either 5/8 or 3/4 O.D.
find the size of grommet you need .
thayre listed by I.d and o.d
for the 5/8 id one ,its usually got a 7/8 (.875) O.D Mouser.com part #534-752
for the 3/4 I.d. grommet, Its 1 1/16 (1.062)O.D. Mouser.com part #534-755



with a drill...
locate and mark the hole locations.
drill a pilot hole with a 1/8 (.125) drill
Then move up in size 1/8 at a time till i get to the desired diameter.

with a dremal...
locate and layout the holes locations and O.D.
drill the 1/8 pilot hole.
remove the material with a burr attachment to the desired O.D.
go slow and keep a steady hand,your workpiece should be secured to keep it from moving and grabbing the tool.
when it grabs it usually gouges or shatters the plexi.

Oh and wear eye protection ...Good luck.

Thanks RBIEZE!

Maybe use masking tape over the area you are cutting, both sides.

I never drilled holes in plexi... but would a hole saw work? Or would it melt the plexi? Its the way I would go if it doesn't melt the plexi. Then just pop the correct size groumets in.

Quote: Originally Posted by Bouve124 I never drilled holes in plexi... but would a hole saw work? Or would it melt the plexi? Its the way I would go if it doesn't melt the plexi. Then just pop the correct size groumets in.

Clamp scraps of plywood either side of the plexi & use the holesaw through them

Quote: Originally Posted by Jonny English Clamp scraps of plywood either side of the plexi & use the holesaw through them

Yeah I thought of that after I posted....