How to Make a 4-Sided Plexiglas Case With a Door

Cut the Plexiglas into the desired size using a skill saw or jig saw with a fine blade. You will need six pieces of Plexiglas when you are done: a top and bottom that are the same size, two side pieces cut the same size and a front and back the same size. You can use a scribe on thin Plexiglas instead of a saw.

Prepare the Plexiglas by sanding the cut edges with a fine-grit sandpaper to even out any jagged areas. Avoid sanding the flat surfaces of the Plexiglas because it will scratch the surface. Wipe the Plexiglas clean with a wet cloth. Tape the cut pieces of Plexiglas into the desired box shape using painter’s tape.

Glue the Plexiglas together one side at a time by removing the tape from one side and gluing the pieces together with solvent cement. Repeat this process on all sides except for the front, which should be left unglued so that a door can be attached. To prevent glue from accidentally getting on the door, remove it temporarily. Allow the glue to dry for at least 24 hours.

Hold door hinges against the inside front of the box and mark the holes with a marker. Using an appropriately sized drill bit, drill holes in each of the marks, taking care not to drill all the way through the Plexiglas. Attach the hinges using screws.

Mark the door for drilling by holding it up to the hinge and marking each hole. Drill holes into the marks. Attach the door to the box using screws.