Plexiglas is clear like regular glass and is often used by home owners and hobbyist. It is a form of acrylic making it flexible so it can bend around corners. Plexiglas is perfect in replacing motorcycle and/or boat windshields. It comes in different thickness, so you are sure to find the size you need.
I have a piece of Plexiglas in my screen door. The window was small, about 8 inches by 12 inches. The original glass broke out when my dog’s chain accidently hit it. I came across it in the basement one day when I was looking for some glass to cut.
Since I couldn’t find glass, I decided to save some money and use what I had on hand. I cut the Plexiglas and used that in my door. It works great. The dogs can see out, and I don’t have to worry about it breaking like I did when it was glass.
Choose the Right Blade For the Job
Cutting the Plexiglas in not hard, but it is important that you take care and choose the right saw and blade. When cutting through the Plexiglas, care must be taken to use the right-sized saw blade, otherwise you risk having the blade heat up. If that happens, you will melt the Plexiglas, making it unusable.
Protect the Plexiglas from Scratches
Cover the work area with a sheet to protect the Plexiglas from being scratched. Also, leave the protective film on the Plexiglas to protect the surface from being scratched. Cover both sides of the Plexiglas with masking tape. This not only protects the surface from being scratched, it will keep the edges from chipping while it is being cut.
Trace Out a Pattern
Make a template of what you are going to use the Plexiglas for. . if you have your existing window or windshield intact, cover it with poster board or light cardboard. Tape the pieces of cardboard together to make the pattern longer than what you need. Place the windshield onto the poster board, and trace around it with a pencil. Mark any areas where holes need to be drilled. Use a carpenter’s square to make the lines straight and the corners exact. Cut the pattern out on the lines you drew.
Transfer the Pattern
Lay the pattern on the new sheet of Plexiglas. Under the pattern, place some blue masking tape on both sides of the Plexiglas. You will want the pattern line to go right down the middle of the tape. This is done for two reasons. It protects the Plexiglas from being scratches, and it also prevents the Plexiglas from chipping as you cut.
Lay the pattern on the Plexiglas and then draw around it with a grease pencil.
Cut the Plexiglas
Now it is time to set up your power saw. Choose the right blade for the job. This depends on the thickness of the Plexiglas. If the Plexiglas is thick, then you need to use a blade with fewer teeth. A thin sheet requires a fine-toothed blade with more teeth.
To make sure you have the right blade for the job, talk to the professional at the store where you bought your Plexiglas. If you already have the sheet of Plexiglas, like I did, take a measurement of its thickness and then ask a professional which blade works the best. The last thing you want to do is use the wrong size and melt your new window or windshield. Be sure to tell the clerk if you are using a band saw, saber saw or a jigsaw.
Start up the saw and begin cutting through the material, slowly and carefully.
Sand and Install
When you have the piece cut out, you will need to sand the edges. Stand the window or windshield in an upright position. Use 220-grit sandpaper. You can sand the edges by hand, or if you are very careful, you can use a palm sander. Remove the masking tape and protective film when you are finished sanding. Or you can just start to remove it around the outside perimeter until you have it installed. It will help keep your new window scratch free.
Now you are ready to install your new window.
Source:
Plexi Class: Cutting-Edge Projects in Plastic”; Tonia Davenport; 2008