Lexan windshield

[spacemanpete]

Anyone ever cut a windshield out of Lexan?<br /><br />Any tips? Anything to look out for before I dive in?<br /><br />Thanks, Peter

 

[lovell]

Re: Lexan windshield

You can cut lexan with any sharpe saw. It can be sheared. Bending it is another story, use a heat gun and be careful it will blacken and get moisture marks if to hot, it will bend nice if you take your time.

 

[bh357]

Re: Lexan windshield

What type of contour do you need to form for your windshield? Polycarbonate (Lexan is the GE trade name for their resin) can be cold bent up to a point. Generally for cold bending polycarbonate, the radius of curvature should be 100 times the material thickness.<br />You may also want to look at acrylic (Plexiglas) as an alternative. Acrylic doesn't have as high of impact resistance as polycarbonate, but acrylic is more scratch resistant and generally has better uv resistance. Acrylic can't be cold bent as easily as polycarbonate, but is easier to thermoform (polycarbonate likes to absorb moisture).

 

[bh357]

Re: Lexan windshield

Sorry, I forgot to address the cutting. If using a bandsaw or recipricating saw, use a blade with 10 teeth per inch and 0 degree rake. Watch for smearing at low blade speeds, especially on a bandsaw.

 

[airman]

Re: Lexan windshield

A layer of saran wrap (or similar) will protect the material while you work on it.

 

[bhalsdorf]

Re: Lexan windshield

If you want to use Plexiglass there is a write up I did on making a windshield and oven to form it. It is located at:<br />www.fiberglassics.com<br />under General Info/ How To's<br /><br />I made 2 windshields for my 1958 True Ski. Only cost me about $60 - $70 including material to make the oven.

 

[spacemanpete]

Re: Lexan windshield

I have to get just under a 60 degree angle. The windshield I'm replacing is one piece that will be framed into a fiberglass cabin.<br /><br />Thanks for the tips. I'll let you know how it goes.