Cutting Lexan

[Ajeauxdn]

Whats the best way to cut this stuff perfect, all a reamer seems to do is ounch a hole in it, whats the point of that if I want to cut out a square, in the windshield? I just want to cut it right and make it look professional, any tips on how to do this right the first time.

 

[SkyMaxx]

First, you do not want to cut a square (at least one with right angles...or any angles at all). Angles cause weakness or areas of high stress in the lexan. When you take a hit, the corner of that square will be the area that the first cracks develop.

Stick with rounded corners and circular/oval-shaped holes.

 

[kwong2001]

Well I trim the body with lexan scissors, then take a dremel with a sanding bit and fine tune the body. Works great...now if only I could center the body absolutely perfectly on the car....

 

[Ajeauxdn]

Ok so basiclaly cut and oval and then sand the edges smooth

 

[SkyMaxx]

That sounds just right. It might not look as automotive as you'd like, but the body will last longer.