How to Cut Coroplast With a Jigsaw

The versatility of a jigsaw allows for making straight as well as curvilinear cuts in a variety of materials including wood, metal and plastic. Using the correct blade, it is possible to cut Coroplast plastic sheets quickly with a jigsaw. However, since Coroplast sheets are lightweight and made with thin plastic, the wrong jigsaw blade can easily result in a tattered edge. By choosing the appropriate blade and using standard jigsaw techniques, you can finish your Coroplast project efficiently and safely.

• 1

  Place the sheet of Coroplast on a flat surface. If you need multiple pieces of the same shape, stack three to six sheets to cut at the same time.

• 2

  Trace the shape to be cut on the Coroplast with a pencil. Use a straightedge for rectangular shapes or a template for more complex shapes.

• 3

  Slide the Coroplast from the table top so the drawn line is sitting 2 inches beyond the edge of the table. If there is a lot of overhang beyond the line, support the opposite end of the Coroplast with a sawhorse.

• 4

  Clamp the Coroplast to the table with two clamps to keep it in place while you cut. Place a towel between the top jaw of the clamp and the Coroplast to prevent scuffing. Do not over-tighten the clamps, as they can crush the Coroplast.

• 5

  Push on the lever at the nose of the jigsaw and insert a fine jigsaw blade with teeth that point downwards.

• 6

  Put on safety glasses to stop shooting plastic bits from striking your eyes.

• 7

  Position the blade on the edge of the Coroplast, lining it up with the cut line. Engage the trigger to run the blade at full speed and follow the cut line carefully and at a steady pace.

• 8

  Support the overhang with a free hand when approaching the end of a cut to keep it from falling and causing a rip in the edge of the Coroplast.