I would like to know what is the best way to cut a pattern out of a sheet of FRP wall material? What tool would best suit the purpose? Any ideas?
it can be drilled or cut with any type of saw and wood blade, the finer the tooth, the better. Cut slowly and have the material well supported to minimize tear-out
Thanks for the information. I'll probably use a saber saw with a fine blade and a carbide hole saw to cut the hole. I'll make sure that the FRP is properly supported and stabilized.
There are special tools for cutting sheet metal and even FRP, which will give you a smoother cut than a jig saw would.
Google it and learn about it.
Straight cuts I use as high a speed and as many teeth as possible on the saw going slow from the back so that any chipping is hidden. Holesaws I go from the front since the biggest danger of chipping in on break-through. I do radius cuts with a sanding drum mounted in a drill if I can't use a holesaw; slow but easy to handle.
Like laminate countertops, this is a frangible material very prone to chipping if you don't treat it right. It gives an industrial look but in low-end rentals it's the best tub-surround you can get for your money- darn near bomb-proof, waterproof, and much cheaper than tile or regular replacement of war-torn acrylic kits or panels. I'm still waiting for them to make more colors and a smooth-faced panel or at least a less 'industrial' texture; then it will be my surround go-to for anything not tiled.