polycarbonate (aka lexan) help

[NismoMax80]

i have 2 sheets of poly i bought 2 years ago to make underbody panels. with one sheet i can cover under my front bumper back to my oil drain plug. i can also block off my lower grille opening and beside the fog lights with excess pieces.

i plan to use already existing holes on my subframe to add fasteners. seems like i will have to drill holes into my fiberglass bumper cover to use either fasteners or zip ties. i want to be able to remove the panel so i may access my transmission plug or other things from below if needed.

for my lower grille, i have no idea how to attach it. i still need to add mesh to the opening, but i might place the poly directly behind it. any ideas?

i do not want to block my top grille. (maybe something temporary during winter but not something "permanent") BUT i do want to add a horizontal piece maybe slightly inclined to keep the air flowing up and not down on top of the panel i add below. i think coroplast might be best to use here with some gorilla tape on the bumper to hold it.


any suggestions to help me cut, (hope i don't have to shape ), and attach the polycarbonate?

[justpassntime]

Lexan or plexiglass is easy to cut or shape. I used a jig saw with a fine tooth blade in it, in the past I have also used a scribe to score plexiglass about half way through and break over a table edge. Experiment with a small piece first. But I like the jig saw. I used masking tape for the guide lines and to protect the lexan from scratches. It also helps to keep the chipping if any to a minimum. You can also use a belt sander to help clean up edges and with final fit.

To shape it get a hot air gun (like a blow dryer but hotter) heat it where you want the bend and do what you will. Heat it slowly though so you don't bubble the lexan.

For the grill I would make some brackets of some sort. Maybe a "j" hook shape to hook behind the back of the grill trim and use a screw from the front of the lexan.

[NismoMax80]

thanks for the tips.

i think i will try to glue the lexan behind the grille. i don't see that i will have to remove it, except for maybe repainting the mesh and bumper in the future. i'll consider some L brackets. maybe 2 for the top. the other sides would be visible on the outside bumper.

How about 2-4 L brackets on top and a couple zip ties to the mesh. hopefully my shop guy can firgure something out if i ever get my mesh to install.

i want to cut into my bumper as little as necessary.

hopefully i can secure the bottom piece it to the bumper with only 6 plastic push screws, 8 at the most. i should be able to get 6 more attaching to the subframe.

[justpassntime]

Originally Posted by Ville80

thanks for the tips.

i think i will try to glue the lexan behind the grille. i don't see that i will have to remove it, except for maybe repainting the mesh and bumper in the future. i'll consider some L brackets. maybe 2 for the top. the other sides would be visible on the outside bumper.

How about 2-4 L brackets on top and a couple zip ties to the mesh. hopefully my shop guy can firgure something out if i ever get my mesh to install.

i want to cut into my bumper as little as necessary.

hopefully i can secure the bottom piece it to the bumper with only 6 plastic push screws, 8 at the most. i should be able to get 6 more attaching to the subframe.

Sounds like your on the right track. I don't like cutting or drilling if I don't have to. I usually find away around it, even more important for you since your car is much newer than mine. Good luck.

[cfg83]

justpassntime -

Originally Posted by justpassntime

Sounds like your on the right track. I don't like cutting or drilling if I don't have to. I usually find away around it, even more important for you since your car is much newer than mine. Good luck.

Me neither. I have Dremeled into parts of the car like the bumper cover, but I usually make a hole where it can't be seen cosmetically.

CarloSW2

[NismoMax80]

does anyone know if it's possible to glue polycarbonate to itself?

i'm thinking of adding air dams under the underbody tray i'm adding. not sure if having a narrow strip at a right angle is even possible?

maybe i could use gorilla tape on both sides. oohh, if i can find some small L brackets i could screw it together. and the tape would reinforce it!


so i guess my real question now:
since my tray will be so low to the ground, will an air dam underneath be effective?

the oem tray had one, but mine will reach 7" further back. it is also further forward and closer to the ground. this tray will actually be lower than the stock tire air dams. i'm kind of concerned if a 1" one would be scraped off?

[justpassntime]

There is glue for lexan and plexiglass. Do a search for glues for those materials and you will fing what you need or you can find it any where that sells those materials.

I remember in jr high we glued plexiglass together and it dried clear. But of course I was a teenager then and didn't pay real close attention. I was only in that class cause the teacher was HOT! I was paying more attention to her I guess.

[NismoMax80]

found this online
Weld-On #40 4-oz. Kit but it will cost me $19.
guess i can look around for an "offline" store

[NismoMax80]

i stopped by the sign shop today to get my cardboard that was with the coroplast i grabbed. talking to him about lexan glue, he just gave me some Weld On 3 liquid and the syringe bottle to apply it! Weld-On #3 4 oz. Can

so now i can add an air dam to my front tray, then fins foe a rear diffuser.
if i make the diffuser, i guess i'll paint it black.

anyone know if polycarbonate is paintable?

[justpassntime]

It is but I would use something like plasticote to paint it with. Or it may peel when the plastic expands and contracts.