Scroll Saw Cutting Acrylic Letter Templates

26 Oct

Here’s a nifty tip from  Canadian Woodworking (don’t forget to visit their site!)


Lettering templates

by Ted Duquette

Here is how I make lettering templates out of 1/16″ plexi- glass. I use a computer to print out the lettering patterns first (you could also draw them by hand). The trick to cutting Plexiglas successfully is to buy the type that has the brown paper on both sides of the Plexiglas.


You can glue your pattern on to the brown paper or you can draw the lettering right onto the paper. I use a #5 scroll saw blade with 12 teeth per inch to do the cutting. I set my saw at about half speed. If you only have a full speed saw, it can still be done but you will need to take a lot more care to ensure clean cuts. Take your time when cutting out the lettering – remember this will be the master template for all your future lettering. If you can’t get the brown papered version use un-backed Plexiglas. However, before you start cutting cover the glass with masking tape. This helps cool the blade while cutting so the Plexiglas doesn’t melt. I have made about two dozen of these lettering guides in different sizes and fonts and use them a lot in the shop.


Posted by on October 26, 2007 in Acrylic, DIY, Fabrication, Recreation


2 responses to “Scroll Saw Cutting Acrylic Letter Templates

  1. vista icons

    November 19, 2007 at 10:15 am

    thank you

  2. james

    June 23, 2008 at 8:42 pm

    Thanks for the guide. When you say you set your saw at half speed, what does that equate to in Strokes Per Minute. The saw I just bought does 400-1600 SPM. I’ve seen other people say use lowest rpm to cut 1/8″ cast acrylic. Thats what I have to cut. SPM info and any other pointers you could give would be great – thanks again


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