Cutting Lexan for NACA ducts?
 

So I bought a couple of Lexan windows last week - it is 5mm thick MSA-spec proper Lexan to go in the rear quarters of the circuit Bug. I am wanting to cut them to install some NACA ducts in each one. Can anyone offer any tips for the best way to do this - is a Jigsaw OK? Obviously making sure I don't scratch it is the easy part (tape on the jigsaw foot, etc). My main issue is getting a good edge - I was thinking of a medium or fine wood blade, starting from drilled holes at each corner, and then finishing up by hand. I read that if I am not careful the Lexan can melt as I cut - is that right? I also read that after hand sanding I can finish up the edges with a gentle flame to turn the edges glass smooth - is this correct?

All hints and tips gratefully received :)

I used a medium-coarse metal blade in a jigsaw to cut mine...can take a photo if you like. The lexan will melt, but only at the cut...it basically balls up in front of the blade. How hard you push into the material will determine how the melting occurs. It won't damage the overall look of the piece though.

Your lexan should have come with a protective film on both sides, if it didn't...return it. If you pulled it off, you're hooped. Nothing scratches faster or easier then lexan. Tape on the foot of your jigsaw will still scratch bare lexan. I didn't use the flame trick on the edges, it's a race car and even with the level of detail I was aiming for you can't see them. I have used the flame technique on other pieces...and all I have to say is practice, practice, practice on scrap pieces and then be super careful.

-Dave

Aha - if in doubt, open it and read the instructions! I had left the windows all wrapped so as not to risk getting them damaged. After your tip to check they had the protective film on I opened them to find that, yes they have film on both sides, but also that the film on one side gives instructions on cutting! :rolleyes: Also I now realise why it is left and right glass when it is the same shape and flat - they have MSA approval markings on the inside, so making them left & right...

And to think I am always telling my customers to read the manual/instructions first - D'oh!

Picture of the final product please!!!!

Jason