Reaming holes in Lexan - gotta be a better way

[Coelacanth]

In the past, I've used an X-Acto blade to ream holes in Lexan, by rotating the blade and gradually widening the hole. This works great until the hole gets to be a certain size--about 4 or 5mm or so--then it doesn't work so well.

I thought I'd solve my body-reaming problems by buying a Lexan reamer, but frankly, that thing doesn't even work as well as the X-Acto knife. I found that I had to press rather hard to get the reamer to work at all, the end result was that the resulting holes had a pressed-out, cratered look, rather than a nice, flat, clean hole.

I doubt using a drill will work, I imagine the bit would have a risk of catching and tearing the Lexan.

So, what works better than the above methods??

[badattitude]

What lexan reamer are you using?

Mine works real good. In fact, I have reamed a hole in a rubbermaid tub with it. The one I have is a HPI.

http://www.rcplanet.com/HPI_Body_Reamer_p/HPI9087.htm

[shodog]

I use a dremel with an angled stone bit

[Coelacanth]

I'm not quite sure what brand it is--picked it up at the LHS. Shodog, I like your idea, thanks, I'll have to try that.

[bearrickster]

I just use these.
http://www.harborfreight.com/3-piece-titanium-nitride-coated-high-speed-steel-step-drills-91616.html

[vintage AE]

The O'Donnell Reamer works awesome

http://www3.towerhobbies.com/cgi-bin/wti0001p?&I=LXVHM4&P=7

[THEYTOOKMYTHUMB]

The O'Donnell Reamer works awesome

http://www3.towerhobbies.com/cgi-bin/wti0001p?&I=LXVHM4&P=7

This one is excellent. Mine's a different brand(can't remember which right now), but borrowed one of these at the track one time and it works better than the one I own. Mine works ok, but I always go back over it with the dremel to smooth the edges.

[YZ-10]

I bought a Hudy reamer some years ago, it works perfect every time

[Coelacanth]

The one I bought, it seems as though the edges don't "bite" enough. About the only force that causes the hole to widen is downforce, which causes the cratering effect mentioned earlier.

[vintage AE]

wow, I thought they were all the same. Like I mentioned, the O'Donnell one is good...smooth clean holes and a very sharp reamer. You just have to twist it and use little pressure. My wife cut herself with it because she wanted to see what it was. She pulled the cover off and stabbed herself in the hand she's fine

[scr8p]

I use a dremel with an angled stone bit

x2

[Lowgear]

I didn't realize that body reamer technology had advanced since I bought a Duratrax one something like ten years ago. I definitely will be buying that O'Donnell one.

[THEYTOOKMYTHUMB]

Mine's a Dubro and it's not great. It's ok once you get to a certain depth, but if you want to make a small hole it sucks. I'm waiting to put it thru my hand trying to start a hole...

[Coelacanth]

Mine's a Dubro and it's not great. It's ok once you get to a certain depth, but if you want to make a small hole it sucks. I'm waiting to put it thru my hand trying to start a hole...

That might've been the one I bought. It functions more as a hole punch than a reamer.

[Erich Reichert]

Of all the reamers I've ever used (and lord knows between my 26 years in this hobby and having built every car RC Driver reviewed between 03-05 I've used them all) my favorite of all time was the red one Dynamite used to sell (they don't anymore). It had a pin sharp point on it and had a very sharp 3.5" flute on it. I'd say out of the ones that are out there now...

1. Hudy. I'm REALLY partial to their tools in general. I don't know that I've EVER had tools as nice as Hudy's. A little pricey but they feel like no others in hand.
http://www.hudy.net/xhudy/news/newsdesc.php?news_id=157&kategoria=157

2. THS. This ones pretty nice (as are all of their tools) but it's a little cheaper. What's nice with this one is it closes up into its handle so it doesn't take up much space and you won't gouge yourself trying to find it when your working. Nice middle of the road price.
http://www3.towerhobbies.com/cgi-bin/wti0001p?&I=LXFWE8

3. GH. This one, in my opinion is pretty much a copy of the old Dynamite one. To be honest I wouldn't be surprised if they are actually made by the same place... good old Taiwan for you. It comes in a bunch of colors and its the cheapest.
http://www3.towerhobbies.com/cgi-bin/wti0001p?&I=LXAELY&P=7