I am constructing artifact display cases. That rquire plxiglas lids. What is thr safest, cleanest method to cut the plexiglass froma 1/4"x4'x8' sheet of plexiglss? They all would be straight cuts...

Well, depending on the size of the pieces needed. I like to use my bandsaw with a fine tooth band. Then if it needs to look really good, I use the stationary belt sander and grind the edges with fine grit belts.

They sell a tool for cutting plexiglass, it is a little tool about six inches long. It has a really sharp blade. Now this way is a little time consuming but if you have a flat surface and a straight edge to guide you it would be worth it for the results, the only advice I could give is make sure you leave the protective covers on and don't try to score it all at once. About four to five passes and it should snap easy. Reply if you have any other questions

A carbide tipped table saw blade does an excellet job. The fine toothed bandsaw blade will melt the edges.

You might try a cut with the blade on backwards. This is usually done when cutting laminate. It may or may not make a better cut.

If you need to drill large holes use dishwashing liquid with a very small amount of water and brad point bits or Black and Decker's Bullet bits. I had to do a bunch of 5/8 holes in polycarbonate and I had to grind a bit from a regular drill bit. What fun.

For the edges, you can fire polish them after you knock off the burrs with a file and possibly some sandpaper.

If you haven't bought the sheet yet, price buying it cut to size at a glass shop. I have had better luck cutting glass than Plexiglass.

I cut all my plexy on a table saw,slow pass and yes it smells:)

As long as it was warm,it cuts just fine,lower temps and I had a few splits.:((something you don't want to have with a 4X8 sheet running somewhere around $100 per sheet)

Although I haven't heard of the tool mentioned above,I would look into it,cold cutting is what the glass companies do,sounds promising.

Ken