Quote:
Originally Posted by JJMunoz
Basjoos, besides a heat gun, what did you use to form the lexan to the aluminum framing for the rear hatch windshield? And what did you use to cut such precise angles? A sawzall? I don't believe a box cutter's sharp enough to cut through it without it taking hours for just one cut. :/
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1/8" thick lexan is stiff, but moderately flexible, so I just put most of the curve into it using hand/arm pressure and then heated up the curved section to relieve/relax the stress of the newly created curve. Lexan has a fairly narrow temperature range between where it softens/becomes easier to bend and where it starts to burn/bubble from getting too hot. To cut the lexan, I used a jigsaw with a faily fine blade with some soft material covering the shoe to keep it from scratching the lexan.