Making a box out of acrylic

[Walt Langhans]

Time to tap in to the vast experience pool that is Sawmillcreek

I want to use 1/8" acrylic to make a box. I figure I'd cut the sides to it has notches on some sides and tabs on the other to fit everything together. Simple so far, but here's where the question comes in. How to hold it together?

I've used acrylic glue before and if the edges are flat then it doesn't work to well, although I have seen different viscosity for the glue that claim to 'fill gaps' but I've never used them. I'm a bit concern that the kerf that the laser will leave could mess up the gluing process.

Has anyone tried this before and have some advice?

[Martin Boekers]

Maybe a UV cure adhesive would be better?

[Glen Monaghan]

Make a couple of test pieces, one with a notch and one with a tab, to verify a snug fit. Adjust either the notch or the tab piece, re-cutting until you get proper size/fit. Then use a syringe to apply the water-thin Weld-On 3 to the joints, carefully allowing it to wick into the almost-non-existent gaps. Don't over do it so that the liquid overflows or drips back out, and don't have the joint sitting on a surface because that will cause the Weld-On to wick right back out and spread everywhere. With a good fit, smooth edges, and care, it will produce clear, solid joints.

[George Carlson]

I would avoid using the notching technique for Acrylic. The main reason the notches are used for wood is because end grain does not glue well. The notches and tabs are glued on the edge grain. Just make tight fitting butt joints and use the solvent welding method with the Weld-On. Do correctly, the joints will be transparent. One note, you may have to stress relieve (anneal) the acrylic before gluing to prevent crazing.

[Larry Bratton]

I've made lots of acrylic items using Lee DeRauds box joint macro (you can find it here) and acrylic cement. We even made a bunch of overhead signs for a casino that I cut all the parts out of 1/4" acrylic and they were assembled with Calsak's SC125 solvent cement. They were all cast and we had no crazing. Super Glue works well too.

[Walt Langhans]

Thanks for the input guys!