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i bought a 4'x8' lexan blank sheet to make my windows out of. 1/8" thick. whats the best way to cut this stuff once i have the wondows traced out on it? my friend says he scores and bends plexiglass to cut it and it breaks at the score mark but i doubt this stuff will act the same way.

my only idea so far was to use a hack saw or band saw with the blade in backwards. any of you guys who cut your own windows know a good way to cut them?
 

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i bought a 4'x8' lexan blank sheet to make my windows out of. 1/8" thick. whats the best way to cut this stuff once i have the wondows traced out on it? my friend says he scores and bends plexiglass to cut it and it breaks at the score mark but i doubt this stuff will act the same way.

my only idea so far was to use a hack saw or band saw with the blade in backwards. any of you guys who cut your own windows know a good way to cut them?
Table saw and 80-120 tooth blade.I cut it every day at work.bm
ps..leave the paper on until right before the install...itll scratch...also...never use paper towels to clean lexan...its like rubbing a 2x4 on it!!Use a cotton cloth and water
 

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thanks. also good to know with the paper towels as that is probably the first thing id grab to clean them haha.
 

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They also make a cleaner for lexan that keeps the swirl marks out of it. I don't remeber the name of it, but it works great.

I have cut it with a jig saw also.
 

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They also make a cleaner for lexan that keeps the swirl marks out of it. I don't remeber the name of it, but it works great.

I have cut it with a jig saw also.
the cleaner is called novus they make a light rubbing compound for heavier scratches and a cleaner/scratch remover for light scratches. availible at most Harley dealers
 

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the cleaner is called novus they make a light rubbing compound for heavier scratches and a cleaner/scratch remover for light scratches. availible at most Harley dealers
There are actually 3 grades of Novus. One for cleaning and polishing, one for removing light scratches, and one for removing heavier scratches.

You can buy Novus at a lot of places other than Harley shops. It's sold at a lot of places.

You can remove scratches from CDs and most other plastics. All the pinball machine supply companies I deal with sell it by the crate to people looking to restore playfield plastics. I use it all the time.

Here's the website:

http://www.novuspolish.com/
 

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There are actually 3 grades of Novus. One for cleaning and polishing, one for removing light scratches, and one for removing heavier scratches.

You can buy Novus at a lot of places other than Harley shops. It's sold at a lot of places.

You can remove scratches from CDs and most other plastics. All the pinball machine supply companies I deal with sell it by the crate to people looking to restore playfield plastics. I use it all the time.

Here's the website:

http://www.novuspolish.com/
we only carry #1 and #2 at the Harley dealer I work at:D
 

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If you want to polish the edges after you cut them, use toothpaste after you rub them down the best you can with fine sand paper. You won't believe how good you can make the edges look. No Joke
 

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I've used it all to fit lenses, displays, faceshields, and windows and windshields in cars...even small cut-off wheels for small diameter corners, grooves, etc.

I use Plexus for my polycarbonate - nothing I've tried works better. You can find it online, motorcycle shops or if you live near a small airport, they usually have it in the pilots equipment stores.
 

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I only use Mylar coated lexan on cars. Dupont makes that and others offer the coating in other names but it is coated. It is very scratch resistant. I use paper towels and windex to keep my windows clean and after 9 yrs now they look like new except for a few rock marks on the windshield. The Beretta was built in 1995 and those windows still look like new as well. I cut mine with a band saw and a sabre saw. I work the edges with a sand block and 200 grid sand paper. That's how most guys I know do it as well. RM
 

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I draw the pattern on the new piece (which still has the protective paper film on it) and then cut it close to the line with a band saw. Then I put the piece on a belt sander and finish it to the pattern taking care not to get the Lexan too hot or it will start to melt. Then I do a final buff to the edges with a pedestal buffer.

Of course it's nice having all the equipment to use at work to do it.;)
 
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