How to cut plastic letter trays?

[zonian149]

I am using some old plastic letter trays to hold some of my scanners, but the trays are too long for the scanners. I want to cut off about 4-6 inches off each tray and was wondering what would be the best tool to use to cut them off to the desired length. I would like them to be as clean a cut as possible. I have hacksaw, jigsaw, miter saw (manual) and various othter tools and was just wondering what would be some suggestions. Thanks for the help.--Gary

 

[pogbobo]

how about a dremel? it might take a while, but it will be pretty precise

 

[N467RX]

If it's just plastic you might want to try a hot x-acto

 

[mjthomas59]

A good razor might work if the plastic isn't that thick, but my guess is you will giveup or cut yourself and then give up before you succeed, especially having 5 of them to do. I would probably try the hacksaw with a very fine blade on it and have a lot of patience.

Its difficult to tell the strength of the material from the picture, but if all your radios can fit in them and the bottom one isn't collapsing or leaning over then i would guess it is too thick for a boxcutter/razorblade tool. The right type blade on a tablesaw would atleast get the hard part of cutting out of the way and it would be a straight a cut as you could get... but i'd try the oldfashion hacksaw first and see how it goes.

 

[landonjensen]

Nice idea for a install!

 

[LordJ]

How about a reciprocating saw with a metal cutting blade, and stand them on their side to cut them one by one...

 

[Thayne]

A bandsaw with a fine toothed blade (like you would cut fairly thin metal with)

Of course if a person had a saw like that they wouln't be messing around with cutting up plastic trays--

 

[whls3]

Bandsaw is the way to go. A wire brush will clean the blade afterwards.

 

[n8emr]

I personally doubt your going to get a good cut with anything on that plastic. Its hard and will ball up no matter what you do. Even if you sand it, it will have a raw edge. If you must cut it then a bandsaw with metal cutting blade. what ever you use make sure its a fine blade and moving fast.

 

[k9rzz]

I'd go with a Dremmel ... quick, exact, although it will leave a rough edge. Just cut a little long so you can sand or file the burr down.

Nifty idea though!

 

[jhooten]

My opinion, for what it is worth, is to leave them like they are. It gives room for the cables to exit straight out the back of the unit without being bent and kinked by the back of the tray.

 

[gsownsby]

I think JHooten has it right...

They look good as-is and they will be hard to cut "at home" and look as professional as they look now. I'd suggest leaving well enough alone. ;-)

 

[af5rn]

Not to jack your question, but I just wanted to say plus 5 for a creative idea! I just stack my radios on top of each other without any shelving, but they're all the same model, so they fit well. You don't have that luxury, so that was a pretty cool solution!

 

[KC0QNB]

Good idea, another one for the greatest tips forum, sorry I am late I just found this thread.

 

[brentoli]

Find a hot wire cutter!

 

[hfxChris]

Just snap them in two with your hands

 

[af5rn]

Chuck Norris would do it with his laser vision.

 

[jon_k]

Go to a place with a carbon laser cutting bench. Looking at $150 minimum for the time though which will offset the whole purpose of this (cheap.)

Any other method will not result in a smooth perfect cut. Burrs with plastic are inevitable.

 

[AK9R]

Neat idea! I have a stack of those trays collecting dust in a closet somewhere. Never would have thought of using them as radio shelves.

Those trays may be getting some of their strength from the back of the tray. The vertical section running across the back acts as a beam that keeps the two sides from collapsing inwards. If you are worried about the cables draped over the edges of the trays, use a hole saw to drill holes in the bottom of the trays near the back. But don't make any big holes in the back of the tray.

 

[2112]

Chuck Norris would do it with his laser vision.

I disagree. I think Chuck would clamp the flat plastic sections of the trays between thicker pieces of scrap wood, hold the trays in his hands to steady his work as he ran it through a fine-blade band saw (with a fence or jig if possible). If he didn't have a band saw, he would still clamp the wood around the plastic and use both hands to steady things, but he would use his third fist (the one behind his beard) to hold a fine-toothed jigsaw for the cutting. Chuck might also consider a hot knife or wire, but then he wouldn't bother with the wood.

Chuck Norris is tough enough to realize that a dremel, a different power tool, or something with big teeth would likely ruin the project. He knows that a razor would be too slow.

Chuck recommends that you leave the trays as they are, though. They look nice and wire management can be integrated by cutting vertical slots in the trays' backs.