Need Advice: How to cut 2 mm styrene sheet

Use a jig saw with a fine tooth blade. I use the table saw and miter box to cut lots of plastic

Matt, thanks for the reply.  I no longer have a jig saw and have never had a table saw.

I'm reduced to Dremel and a ton of cutting tools for it, plus the Zona razor saw.

The more I consider this project, I think I need to cut out a simple rectangle; drill the holes for the hangers, and attach some thin, opaque styrene for the ends (since they provide no structural support--the base and hangers carry the load.)

Thanks, again, Matt.

I've cut plenty pf 2mm (.080") styrene by putting a metal ruler at the location of my cut and scoring the styrene once or twice using a utility (or Exacto) knife with a new blade. It usually will then break cleanly.

The Zona razor saw should do the trick

I have built many models over the years using 3mm 2mm 1mm styrene and for cutting flat sheets I use these tools. Roo 

Thanks, all.  At this point, I'm going with the Zona saw with a fence to make the cuts.  I'm going to start with the basic rectangle of the base and drill the holes at each end; then, using a template, cut the end pieces from much thinner sheet styrene since the end pieces don't support any load.

Lad Nagurney posted:

I've cut plenty pf 2mm (.080") styrene by putting a metal ruler at the location of my cut and scoring the styrene once or twice using a utility (or Exacto) knife with a new blade. It usually will then break cleanly.

I firmly agree with Lad on this one.  "Scoring and snapping" will usually give you a nice even and straight cut.  The styrene can be bonded using a solvent cement.  It's a great medium to work in.  I've constructed rolling stock, locomotives and structures in styrene for years.  My train club used .080" styrene for backdrop supports on our display layout cut from 4'x8' styrene sheets purchased at a local plastic supply house for around $35.

Keep us informed!

Jerry, thanks for the reply. 

I have Plastruct Bondene on hand.  Is that a suitable cement?

Bondene should work well. Michaels, Hobby Lobby, and most art stores carry some sort of styrene solvent cement.

For your thinner pieces, the knife and metal rule will work well. I use my combination square and usually make several light cuts.

Lad