Building a hamaster house: adding a window advice

boardtc · 22-01-2026 01:41PM #1

I am finishing a hamster house made of Malaysian plywood. One of the long sides (100cm x 50cm) I am looking at putting in a window, 85cm v 35cm. I need some advice please!

I found Styrene Clear Polystyrene Flat Glazing Sheet in https://www.diy.ie/departments/styrene-clear-polystyrene-flat-glazing-sheet-l-1-2m-w-0-6m-t-2mm/35393_BQ.prd which is 60 x 120cm. I think this can be cut with a utility blade? Or is there a better/cheaper solution for the window?

Secondly, looking at cutting out the window frame. I have a router (Power Devil, see below) but have never used it. I was thinking I could use a jigsaw to cut a 84cmx34cm window from the front panel and then use a router piece to make a lip for the glazing, is that the best way? Do I need to get putty then to hold in the glaze?

Thanks lads!!

LambshankRedemption · 22-01-2026 01:49PM

https://www.boards.ie/discussion/2058431492/building-a-hamaster-house-adding-a-window-advice

That glazing sheet is 1.2 metres long, 60 centimtres wide. You should be able to cut it easily enough with a utility knife. I think the power devil might be overkill, and might just churn up the polystyrene rather than cleanly cut it.

Tell me how · 22-01-2026 01:57PM

Power Devil is overkill. As previous poster said, use a sharp utility knife.

I would suggest using a metal straight edge that you can fix in position along your cut line and then use that as a guide for your cut.

This video shows what I am suggesting.

(https://www.youtube.com/shorts/9gCutOPGoSs) Copy link and paste in your browser.

boardtc · 22-01-2026 05:07PM

Sorry for my confusing post, I updated so hopefully it reads clearer. The router referred to the second question about cutting the window frame.

@Tell me how good video thanks. Polystyrene and acrylic are different plastics but you think they will cut the same?

Hope someone can help re cutting the window frame, thanks!!

LambshankRedemption · 22-01-2026 05:58PM

https://www.boards.ie/discussion/comment/124170882#Comment_124170882

Well the router will be fine for cutting the wood.

boardtc · 22-01-2026 06:05PM

@LambshankRedemption So my idea of using a jigsaw to cut a 84cmx34cm window from the front panel and then use a router piece to make a lip for the glazing, is that the way to go?

whizbang · 23-01-2026 01:38AM

no harm in trying the router, but practice first.

make a frame with some better wood then cut out your finish piece in one length before you make a frame of it.

Plywood is difficult to router to a tidy finish

boardtc · 23-01-2026 04:17PM

@whizbang practicing on other wood is a great idea, I hadn't thought of that. I have some of the scarp Malaysian plywood I can test on too. Hopefully I can find some time this weekend.

I am unsure what "cut out your finish piece in one length before you make a frame of it." means since I am working with a rectangle window.

monseiur · 24-01-2026 10:27PM

Mark size of window ope on ply, drill 8mm or 10mm holes at 4 corners. Cut out using jig saw. Get a length of pine 'D' shaped moulding 50mm x 6mm (or similar) and cut so that when fixed to inside of ply around window ope. it will stick out say 15mm all around - this will form your rebate for glazing sheet. (which means your shiny router stays in the box😊)

Cut glazing sheet to size, run a bead of clear silicon all around rebate and fit glass. Hold glass in position using glazing slips all around tacked to cut edge of ply and bedded in a bed of silicon mastic. (In case you're wondering - glazing slips are just moulded slips of pine wood and should be off the shelf in B&Q ditto D pine moulding mentioned above)

Due to size of window best use 4mm glazing and cut with jig saw using a blade with fine teeth (otherwise known as high TPI) Don't worry if the cut is not dead straight as the edges will be covered by mastic & glazing slips.

boardtc · 27-01-2026 11:14PM

Thanks a million. The 2mm was €35 for a sheet so I had to stop there. I cut it with utility knife no bother. I abandoned the ice of using a router. Thanks lads!!

Building a hamaster house: adding a window advice

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