Quck answer
To cut plastic fluorescent light covers, follow these steps:
1. Measure and mark the desired size on the cover.
2. Use a straight edge or ruler to connect the markings.
3. Score the plastic along the marked line using a utility knife or scoring tool.
4. Apply gentle pressure to break the scored line.
5. Smooth the edges with sandpaper or a file if necessary.
6. Clean the cover to remove any debris or dust.
7. Install the cut cover back into the light fixture.
Remember to wear protective gloves and eyewear when working with plastic to ensure safety.
When searching for plastic covers for fluorescent lights, it is uncommon to find one that perfectly fits your needs. Flat panels come in standard sizes, but fixtures do not always match those sizes, leaving you with the option of buying a larger one and cutting it to size. Even replacement wraparound fluorescent light covers may need to be trimmed to fit.
While it is possible to use power tools to cut plexiglass and acrylic, it is safer to use hand tools when cutting plastic fluorescent light covers. However, do not worry, as the task is still simple even without power tools.
Trimming Flat Panels
Suppose you have purchased a 2-by-4 fluorescent light replacement lens and discovered that you need to trim an inch from one side and one end to make it fit. To do this safely and cleanly, you will need a utility knife or a scoring tool, which can be bought for under $5. You will also need a tape measure, straightedge, clamps, and a large flat surface to work on. Here is a sample procedure:
- Use the tape measure to mark both ends of the panel at the proper distance from the edge. Align the straightedge with the marks and clamp it down.
- Run the knife or scoring tool along the straightedge five or six times, creating a deeper score line each time.
- Release the clamps and move the panel so that the score line lines up with the edge of the work surface.
- Bend and break off the excess along the score line.
The procedure is similar to cutting glass, but it requires multiple passes with the blade to make a deep enough cut for the panel to break.
Trimming Wraparound Diffuser Fluorescent Light Covers
Scoring and breaking does not work for molded light covers as it is only effective on flat surfaces. You may be tempted to use a power tool like a circular saw or jigsaw to trim a wraparound light cover to the correct length. If using a jigsaw, your chances of success increase if the blade has a diamond grit edge or at least 18 teeth per inch (TPI). Some professionals recommend installing the circular saw blade backwards to minimize chipping.
The safest and most reliable way to trim replacement wraparound fluorescent light covers is to use a hack saw. Place the cover on a flat surface with the open end facing down, mark the cut line with a pencil, and securely hold the cover with one hand while cutting with the other. Apply slight pressure to prevent vibrations and movements that could lead to saw chattering and potential breakage.
How to Make Very Thin Cuts
If you need to trim less than 1/2 inch from the side of a panel and the offcut is too thin to break off, the cutting process can be difficult. However, using a power tool may be the best solution. If you choose to use a circular saw, remember to install the blade in reverse. To ensure stability while cutting, it is important to support the edge you’re cutting by either holding it flat against the cutting surface or placing a 2X4 underneath it if necessary.
The same technique can be applied when cutting a thin piece off the end of a wraparound diffuser. However, using a hacksaw might be easier and safer in this situation.
