Cutting Lexan/Polycarbonate for windshield

[Gtstorey]

I went with DF's tall windshield, and it's obvious that it's to tall for summer use. I think I'm going to try and cut my own. For those that have cut curves in polycarbonate, what have you been using? If jigsaw, what are the details of the blade you used?

 

[Ross]

I used my bandsaw, with a medium wood blade in it. Just practice on a spare piece of polycarbonate... you will figure out the feed rate pretty quick. Anyone want a scratch resistant, UV protected polycarbonate windscreen? I have an extra one coming in the mail.

 

[Gtstorey]

How well do you think a 1/2 inch wide bi-metal blade at 14 or 24 tpi on a band saw would work?

 

[JBINTX]

modding the DF windshield?

So, the heat/humidity monster is about to arrive here, for a long stay, in greater Kicaster (TX). It's not so bad here as what Houston gets (been there done that) but it's bad enough. Which means that the DF-supplied windshield (which was an ideal size in late winter and early spring) will...

dfkitcar.com

You want more teeth on the blade to take smaller chips.

 

[Ross]

It will work well. Watch for heat melting of the polycarbonate. I had a little melt burr on the final edge of the polycarbonate, but it removed pretty easily when cool.

 

[TheNuker]

When I use a saw to cut acrylic which cuts similar to polycarb I use the 32 tpi blades made for steel.

Nuker-

 

[OptimizePrime]

Just cut mine the other day with a T102BF Bosch plexiglass blade from Home Depot with a jigsaw and it looks minty fresh. I didn't even need tape to mitigate tear-out.

You can also sand it with >= 500grit with good results.

Use a utility blade to score the windscreen where you want to cut. Makes the cleanup a lot easier compared to a sharpie/marker

 

[Towerdog]

I'm w Thenuker and used a metal hight tooth count.... but now that a minute ago I learned that there is a special blade for it.... gota have one!

 

[jayrolls]

I used my bandsaw, with a medium wood blade in it. Just practice on a spare piece of polycarbonate... you will figure out the feed rate pretty quick. Anyone want a scratch resistant, UV protected polycarbonate windscreen? I have an extra one coming in the mail.

Is this for the windshield that we have been talking about?

 

[Zoom Zoom]

Is this for the windshield that we have been talking about?

Yes

 

[jayrolls]

Yes

Ok I know I wanted one.

 

[Ross]

Yes, I used a bandsaw on my polycarbonate prototype windshield.
The 4 windshields just came in the mail today. The little sheet at the top is the scrap piece left over from my prototype, and the white is
the protective coating on the TUFFAK AR2 (Abrasion Resistant, 2 sides) UV protected sheets, 2 feet x 5 feet. I still have 1 sheet for sale.

 

[jayrolls]

Yes, I used a bandsaw on my polycarbonate prototype windshield.
The 4 windshields just came in the mail today. The little sheet at the top is the scrap piece left over from my prototype, and the white is
the protective coating on the TUFFAK AR2 (Abrasion Resistant, 2 sides) UV protected sheets, 2 feet x 5 feet. I still have 1 sheet for sale.
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