Recently, I posted about German firm Serrox Technischer Handel’s video showing an interesting alternative to the basic slab-joint method for building an acrylic box. Their technique, which involves cutting 90-degree V-grooves almost all the way through the plastic, has much to recommend it over the slab-joint method, with the exception that they use a very expensive custom V-shaped sawblade to cut the grooves. I wondered, at the time, whether it might not work just or almost as well with a cheap 90-degree V-groove router bit, and with some encouragement from Angus Hines, I decided to try it, myself.
The short version? It works. Here’s how I did it.