Modding - Can you drill into acrylic without cracking it?

Hey guys,

It's a simple question that I wanted to ask the pros about...

I am contemplating building myself a desk PC, albeit a much more simplistic one than you get from the real modders on this forum. It'll consist of two IKEA counter tops (they're stupid cheap for what you get!) and an acrylic surround that'll separate the two. I need some way to secure them in place, and I figured drilling into them would be the best method.

I was thinking of getting an inch thick acrylic sheet, and as long/wide as needed to cover what I need.

What's the best way to go about mounting the two table tops together, without cracking it?

If I do go ahead with this, it'll be a learning curve, without any doubt.

You can use metal bits, but there are proper plexi drill bits if you want to use those. Mount it on scrap wood to prevent the bottom dropping out, put tape on top to stop that chipping depending on size of hole you need you might want to start with a smaller hole then work your way up to the desired diameter in a couple of steps, and lube it up to prevent heat cracking it, water should be fine. And go at it slow, let the bit do the work, don't push too hard.

I use normal bits. The key is having a block of wood clamped to the underside and very little pressure on the bit. I'd add water if using a press or using a big bit. Go slow if using a hand drill and use a guide to stay level. If the bit grabs / starts cracking / pulls as it breaches the underside, your wood backing is too soft.

If you're using a really fast drill you might ned up melting it, I've done that a few times. And as the others said, a scrap wooden block underneath will make it a lot easier and stop it flexing at all (although not really an issue if it's an inch thick.

For Ikea counter tops, look in the damaged section at the end. I picked up a 3m oak covered one for £10.