Cutting Lexan?

"Ron Natalie" wrote in message ...
"Scott" wrote in message ...
If I cut Lexan on a bandsaw, what is the best way to sand out the cut marks
along the cut line? Sand paper? File? I want to make a new windshield and
the cut edge will be the top of the windshield (open cockpit).

Are you sure you want to use polycarbonate rather than acrylic?

I have a lexan windshield on my Jungster. I used lexan because you can
bend it into 3 panels on a sheet metal break. I found some U shaped
rubber channel to fit over the edge so a real finished edge wasn't
necessary. Lexan, however is very susceptible to scratching and
gasoline is death on it. This is my third windshield due to fuel
spills. It will craze almost instantly if gas touches it. I have since
made some covers to protect it when fueling the wing tank.
Ed Sullivan

Ed Sullivan wrote:

"Ron Natalie" wrote in message ...
"Scott" wrote in message ...
If I cut Lexan on a bandsaw, what is the best way to sand out the cut marks
along the cut line? Sand paper? File? I want to make a new windshield and
the cut edge will be the top of the windshield (open cockpit).

Are you sure you want to use polycarbonate rather than acrylic?

I have a lexan windshield on my Jungster. I used lexan because you can
bend it into 3 panels on a sheet metal break. I found some U shaped
rubber channel to fit over the edge so a real finished edge wasn't
necessary. Lexan, however is very susceptible to scratching and
gasoline is death on it. This is my third windshield due to fuel
spills. It will craze almost instantly if gas touches it. I have since
made some covers to protect it when fueling the wing tank.
Ed Sullivan


Treated lexan is more resistant to gas and fumes.
The paper covering is marked "this side outside".

Bill Daniels wrote ...
... a match sized flame ... virtually eliminates any stress risers
that will cause the plastic to crack later.


Eliminate _risers_? Yes. But I can't imagine a better way to induce
latent stresses in Lexan than to use a flame.


Daniel

"Daniel" wrote in message
om...
Bill Daniels wrote ...
... a match sized flame ... virtually eliminates any stress risers
that will cause the plastic to crack later.


Eliminate _risers_? Yes. But I can't imagine a better way to induce
latent stresses in Lexan than to use a flame.


Daniel

I learned the trick from a plastics fabricator - it works for me. Try it on
some scrap. If it doesn't work for you, do it another way.

Bill Daniels

Daniel wrote:

Bill Daniels wrote ...
... a match sized flame ... virtually eliminates any stress risers
that will cause the plastic to crack later.


Eliminate _risers_? Yes. But I can't imagine a better way to induce
latent stresses in Lexan than to use a flame.

The industry has been doing this for years. They call it "flame polishing".
There are even machines for that. We're not talking glass here.

- Holger

I have a lexan windshield on my Jungster. I used lexan because you can
bend it into 3 panels on a sheet metal break. I found some U shaped
rubber channel to fit over the edge so a real finished edge wasn't
necessary. Lexan, however is very susceptible to scratching and
gasoline is death on it. This is my third windshield due to fuel
spills. It will craze almost instantly if gas touches it. I have since
made some covers to protect it when fueling the wing tank.
Ed Sullivan


OK. If you are brake forming lexan into a 3 panel windscreen,
use Hyzod AR2, Marcon, GE MR10 or something similar.
I clean these products with Methanol and/or Naptha. These
are all abrasion resistant hard coated products. Additionally
you can use automotive wax (green can turtle wax is good)
ovet the lexan to add protection beyond what the coating provides.
I even wax uncoated material. It seems to fill minor scratches as
well as making dust static cling less of a problem

Scott.