View Single Post
Old 10-15-2009, 07:16 AM   #335 (permalink)
basjoos
Master EcoModder
 
basjoos's Avatar
 
Join Date: Dec 2007
Location: Upstate SC
Posts: 1,088

Aerocivic - '92 Honda Civic CX
Last 3: 70.54 mpg (US)

AerocivicLB - '92 Honda Civic CX
Team Honda
90 day: 55.14 mpg (US)

Camryglide - '20 Toyota Camry hybrid LE
90 day: 62.77 mpg (US)
Thanks: 16
Thanked 676 Times in 302 Posts
Quote:
Originally Posted by JJMunoz View Post
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. :/
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.
__________________
aerocivic.com
  Reply With Quote