Check if your local Makerspace has a laser cutter.
Here in Wichita KS, MakeICT is my makerspace: costs $25/month, has 3D printers, laser cutters, CNC router table, CNC plasma cutter, CNC metal mill, woodworking shop with tools, metalworking shop with tools, ceramics shop with kiln, sewing shop, electronics shop.
Plywood, exterior grade, or indoor plywood with a few coats of paint. Plus it can be screwed into place
Window a/c or two hose portable will be a lot more effective than single hose portable
I hope you will not use it long term as these portable ACs (not actually Window AC) [are not very efficient.](https://youtu.be/_-mBeYC2KGc?si=rPZEo3eruIK4z1nO)
The place you bought the plexiglass from should be able to cut it for you. Home Depot has done it for me before.
If you try to DIY again, like others said:
*use a fine-tooth blade with your jigsaw
*if it has a “speed cut” option where the blade oscillates a bit, turn that off
*Run painters tape along the length of your cut, cut through the tape
*run the blade fast (if it has speed control), get it up to speed, then move slowly
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I didn't use plexiglass. I used rigid insulation. You buy it for pretty cheap. Pink or blue. First I cut for the void of any window and make sure it fits into the window channels. It should fall down an inch or so. This will allow for easy installation and removal. Then I trace the hose end and cut it out. Attach the hose. Works like a charm and is easy to do and the rigid insulation is insulation that helps keep heat out. I use this in my camper. Ridgid sheets are sold individually at big box hardware stores for a couple of bux.
Ive been cutting plexiglas recently. 3 methods....the scribe tool doing it by hand....pain in the ass but effective..tool cost $14 at home depot.....Jigsaw blade, with a special plexiglas/acrylic blade....a bit faster, but kinda hard to do a longer straight line...lol....Circular saw, with a acrylic/plexiglass blade..much afaster, but it ends up melting the plexiglass if you dont move at the right speed, AND IT CAN OFF GAS so do it with a mask/respirator, and in a well ventilated area...
I just did the same project not 7 days ago. I have casement windows. I used the piece that would attach to the plexiglass and traced around it as best as possible. I then used a large drill bit to make a pilot hole. Drill slowly to prevent cracking. I then used a jigsaw to cut out pieces. Using a jigsaw, you need to make sure that you go slowly. Fast cut works great but the heat just allows the cut to melt the plexiglass and it hardens right back up. I then screwed the piece on to the plexiglass. Silicone on both sides and put it in the window. I have.to leave my window open but it does work quite well.
I had this same issue. That plastic piece in picture #3 can be double sided taped onto the window frame, cut it off it’s too long. Fill the window gap with the plexiglass, which you only need to do straight cuts on now. Fill any gaps with the insulation tape that may have come with your ac unit.
What kind of jigsaw blade did you use? Teeth will cause cracking but an abrasive blade should work fine.
Check if your local Makerspace has a laser cutter. Here in Wichita KS, MakeICT is my makerspace: costs $25/month, has 3D printers, laser cutters, CNC router table, CNC plasma cutter, CNC metal mill, woodworking shop with tools, metalworking shop with tools, ceramics shop with kiln, sewing shop, electronics shop.
If you can stand it, get some foam presentation board. MUCH easier to work with and sturdy. just doesn’t let light through.
Plywood, exterior grade, or indoor plywood with a few coats of paint. Plus it can be screwed into place Window a/c or two hose portable will be a lot more effective than single hose portable
I prefer to use 1” EPS foam board. Easy to cut. Good insulator. A little paint and we’re good!
That reducer funnel on the end of the exhaust hose will Hurt the ac performance.
I hope you will not use it long term as these portable ACs (not actually Window AC) [are not very efficient.](https://youtu.be/_-mBeYC2KGc?si=rPZEo3eruIK4z1nO)
i had the same unit. i used corrugated plastic sheets (like cardboard but plastic) and it was sturdy and kept the air out. also much cheeper.
Ace Hardware or any local hardware store can probably help if you ask.
Caveat is not all hardware stores have glass stations. My local HD doesn’t but the nearest Lowe’s does.
The place you bought the plexiglass from should be able to cut it for you. Home Depot has done it for me before. If you try to DIY again, like others said: *use a fine-tooth blade with your jigsaw *if it has a “speed cut” option where the blade oscillates a bit, turn that off *Run painters tape along the length of your cut, cut through the tape *run the blade fast (if it has speed control), get it up to speed, then move slowly
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Put tape on the plexiglass where you are going to cut and that will help prevent it from breaking. Also being careful helps.
Home depot
I didn't use plexiglass. I used rigid insulation. You buy it for pretty cheap. Pink or blue. First I cut for the void of any window and make sure it fits into the window channels. It should fall down an inch or so. This will allow for easy installation and removal. Then I trace the hose end and cut it out. Attach the hose. Works like a charm and is easy to do and the rigid insulation is insulation that helps keep heat out. I use this in my camper. Ridgid sheets are sold individually at big box hardware stores for a couple of bux.
Ive been cutting plexiglas recently. 3 methods....the scribe tool doing it by hand....pain in the ass but effective..tool cost $14 at home depot.....Jigsaw blade, with a special plexiglas/acrylic blade....a bit faster, but kinda hard to do a longer straight line...lol....Circular saw, with a acrylic/plexiglass blade..much afaster, but it ends up melting the plexiglass if you dont move at the right speed, AND IT CAN OFF GAS so do it with a mask/respirator, and in a well ventilated area...
I just did the same project not 7 days ago. I have casement windows. I used the piece that would attach to the plexiglass and traced around it as best as possible. I then used a large drill bit to make a pilot hole. Drill slowly to prevent cracking. I then used a jigsaw to cut out pieces. Using a jigsaw, you need to make sure that you go slowly. Fast cut works great but the heat just allows the cut to melt the plexiglass and it hardens right back up. I then screwed the piece on to the plexiglass. Silicone on both sides and put it in the window. I have.to leave my window open but it does work quite well.
I had this same issue. That plastic piece in picture #3 can be double sided taped onto the window frame, cut it off it’s too long. Fill the window gap with the plexiglass, which you only need to do straight cuts on now. Fill any gaps with the insulation tape that may have come with your ac unit.