Cutting Lexan
 

Ok so i chopped the rollcage on my Rhino 4" in the rear and 5" in the front to give it a race stance . It looks awesome ! I still need to cut the windshield down and don't want to ruin it . How is this done ? Thanks in advance for your help . deep

masking tape and a fine-tooth jig saw

Yup. Or grinder with a diamond blade. Either way, after cutting, clean up the edges with a file or sandpaper.

I use a 4 1/2" cutoff wheel. Cuts like a skill saw on wood.

I used a fine tooth blade mounted backwards in a table saw, go slow and let the saw do the cutting. Looked like a laser cut when done

You should always have more than one tooth touching your work piece at any given time. If you have a large area to do and want to cut it faster we use a circular saw with the blade turned backwards and you can sort of fudge the two teeth or more thing and still get a good cut without shattering or cracking the plastic.

Yep , I did it this way and it worked perfectly . Looked laser cut . Thanks again for the instructions . You guys rock !!!

If its polycarbonate(lexan brand name) it will work just like wood skill saw, jig saw, table saw, router. Running blades backwards and cutoff blades is a waste of time just tape off the surrounding area so as not to scratch. Also to finish cut edges sand or file burrs I use a wet belt sander with glass grit belts (but I have a glass shop) basically run a sander at a 45 to the two corners. To get a real nice finish take a propane torch to the cut edge and lightly run it across this will even it out and give you that wet look that I'm sure the edges have now
Ps if it's acrylic(plexiglas brand name) you have to be more delicate because it's more brittle than polycarbonate but harder to scratch

Agreed. Clean the lexan first so the tape will stick good. Tape it up good with regular (not blue) masking tape. Use a medium coarse skilsaw blade, Take your time and steer the saw carefully.

When finished, take an old hacksaw blade and drag it across the rough edges to scrape them smooth. Then alternate between the scraping and a file to get the profile you want.

Remove the tape. Fire up the torch, get a clean flame and walk it down both sides of the cut.

MC

Blue tape and a jigsaw.