Procedure on how to shape, bore, and to connect acrylic to aluminum alloy.?

Question

Procedure on how to shape, bore, and to connect acrylic to aluminum alloy.

Answer 1

I've used both acrylic and aluminum in my projects. Acrylic is fairly easy to work with. you didn't specify what kind of 'shaping' you needed. In general it is best to use a high speed, small bite working tool like a router or a 'hack saw' type blade in a jig saw. don't use a circular saw. the back edge of the blade tends to mar the acrylic surface through friction. so use a router whenever possible for long straight edges and where appropriate for edging. Use the jig saw for free form work and finish with a dremel tool at high speed with fine grit sand paper on a drum.
drilling acrylic is tough. you need a press. if you use a hand drill you almost always tilt the drill in the process which causes the flutes to bite into the edge of your hole either snapping a sheet, or maring the surface of a block. plan on using (borrowing) a drill press at high speed.
attaching acryl to acryl is easy. cyanoacrylate (super glue) gives the best looking finish but is brittle. plastic adhesive epoxy is good but often has a yellow tint.
attaching acrylic to aluminum is tougher. the same glues work ok, but not as good as acryl to acryl. better to drill and tap holes to receive screws. either the acrylic or the aluminum can take a thread. the question is the load weight on the joint. threads in alum are stronger.