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cutting windshield

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egp8111

Joined: 25 Mar 2010
Posts: 49

Posted: Thu Nov 11, 2010 6:08 am Post subject: cutting windshield

I'm about to replace the windshield on my KF III.  Whats the best way to make long straight cuts in the Lexan ?



thanks,

EG

sdemeyer

Joined: 31 Jul 2009
Posts: 45

Posted: Thu Nov 11, 2010 6:54 am Post subject: Re: cutting windshield

I tried using my bandsaw on a scrap piece but it came out looking like crap, all chipped up and crooked. Then I used a 4" thin metal cutoff wheel on my angle grinder and followed the line I drew. It came out nearly perfect, no chipped edges and almost perfectly straight. The 4" wheel  wants to go straight and it was remarkably easy. Just take it slow and don't try to cut through all at once. I made several passes, making the cut a little deeper each time until I was through. If you try to cut all the way through in one fell swoop, you will end up melting the plastic.



Scott

Guy Buchanan

Joined: 16 Jul 2006
Posts: 1204
Location: Ramona, CA

Posted: Thu Nov 11, 2010 7:37 am Post subject: cutting windshield

On 11/11/2010 6:54 AM, sdemeyer wrote:  	  Quote: 	
		      	  Quote: 	
		  Then I used a 4" thin metal cutoff wheel on my angle grinder and followed the line I drew. It came out nearly perfect, no chipped edges and almost perfectly straight. The 4" wheel  wants to go straight and it was remarkably easy. 	
 	
 I did it with a Dremel with the Dremel diamond cut-off blade. Go slow and DO cut all the way through. Make sure you have a line to follow and cut 1/32" outside the line. (One blade width.) You don't want to get the blade hot or the plastic starts melting onto it and it no longer cuts. If you need to cut corners do it in sections well outside the cutting line. Once you're done with the cut use a long (11") hard 60 grit sanding block to take the door down to the outside edge of the line. Use this block to sand radii into the corners as necessary. Next do the same with 220 and then 400, just removing the previous grit's scratches. Next use the Dremel buffing wheel with PBC (Plastic Buffing Compound) available by the stick to buff the edge until you can see into the plastic. (Don't let anything get hot, though.) This makes for a sexy finish and one that will resist cracking.

 

 -- 

           Guy Buchanan   Normal   Guy Buchanan   2   13   2010-09-24T17:53:00Z   2010-09-24T17:53:00Z   1   30   173   1   1   202   14.00          <![endif]-->        false            false   false   false      EN-US   X-NONE   X-NONE                                                                                             <![endif]-->                                                                                                                                                                                                                                                                                                                                                                                                                                <![endif]-->      /* Style Definitions */  table.MsoNormalTable 	{mso-style-name:"Table Normal"; 	mso-tstyle-rowband-size:0; 	mso-tstyle-colband-size:0; 	mso-style-noshow:yes; 	mso-style-priority:99; 	mso-style-parent:""; 	mso-padding-alt:0in 5.4pt 0in 5.4pt; 	mso-para-margin-top:0in; 	mso-para-margin-right:0in; 	mso-para-margin-bottom:10.0pt; 	mso-para-margin-left:0in; 	line-height:115%; 	mso-pagination:widow-orphan; 	font-size:11.0pt; 	font-family:"Calibri","sans-serif"; 	mso-ascii-font-family:Calibri; 	mso-ascii-theme-font:minor-latin; 	mso-hansi-font-family:Calibri; 	mso-hansi-theme-font:minor-latin; 	mso-bidi-font-family:"Times New Roman"; 	mso-bidi-theme-font:minor-bidi;}  <![endif]-->   <![endif]-->       <![endif]--> Guy Buchanan

 Kitfox IV-1200 / 582-C / Warp 3cs / Soon to be a 912

 

 

    [quote][b]

_________________
Guy Buchanan
Deceased K-IV 1200
A glider pilot too.

lcfitt(at)sbcglobal.net
Guest

Posted: Thu Nov 11, 2010 7:40 am Post subject: cutting windshield

I just finished fitting my windshield on my Model IV.



I am not necessarily saying this is the best way, but I used some of the 

aviation tin snips and cut within about an eighth  inch of the line then 

used an electric plane to trim to the cut line.  For the cut around the wing 

spar, I used a Dremel with a diamond cut off wheel and a drum sander in the 

Dremel for final smoothing.  The Dremel was the most used tool when helping 

with the neighbors Lancair IV.  Incidentally on the Lancair, the cut line 

was always marked with a strip of blue masking tape.  This way, the cut dust 

would not obscure a drawn line and there was no fear of a permanent mark on 

the material being cut.



Lowell



--------------------------------------------------

From: "egp8111" <egp8111(at)aol.com>

Sent: Thursday, November 11, 2010 6:08 AM

To: <kitfox-list(at)matronics.com>

Subject: cutting windshield



 	  Quote: 	
		   



 I'm about to replace the windshield on my KF III.  Whats the best way to 

 make long straight cuts in the Lexan ?



 thanks,

 EG





 Read this topic online here:



 http://forums.matronics.com/viewtopic.php?p=318964#318964

larry huntley

Joined: 19 Jul 2008
Posts: 149

Posted: Thu Nov 11, 2010 8:02 am Post subject: cutting windshield

If it is Lexan it is polycarbonate and you can cut it with most anything. I 

do mine on a band saw or if it is thin enough I sometimes use metal snips. 

It doesn't crack like acrylic. Still need to drill holes oversize though. 

Larry



---

_________________
Larry Huntley,Dundee,NY
Kitfox 4-1200 N234EE
EA81,AMAX Redrive Warp 3 blade

henrysfork1(at)msn.com
Guest

Posted: Thu Nov 11, 2010 8:55 am Post subject: cutting windshield

I agree with Larry, I have had good success cutting several wind shields using the left right tin snips. 



Dee



[quote] From: asq(at)roadrunner.com

 To: kitfox-list(at)matronics.com

 Subject: Re: Kitfox-List: cutting windshield

 Date: Thu, 11 Nov 2010 10:57:30 -0500

 

 --> Kitfox-List message posted by: "larry huntley" <asq(at)roadrunner.com>

 

 If it is Lexan it is polycarbonate and you can cut it with most anything. I 

 do mine on a band saw or if it is thin enough I sometimes use metal snips. 

 It doesn't crack like acrylic. Still need to drill holes oversize though. 

 Larry

 

 		 	   		     	  Quote: 	
		  [b]

msm_9949(at)yahoo.com
Guest

Posted: Thu Nov 11, 2010 9:08 am Post subject: cutting windshield

Metal shears. Not sexy but fast and easy.

  

 Marco Menezes N99KX

 Hersey, MI

 Model 2 582-90 C-Box 3:1 w/clutch



--- On Thu, 11/11/10, egp8111 <egp8111(at)aol.com> wrote:



  	  Quote: 	
		  

From: egp8111 <egp8111(at)aol.com>

Subject: cutting windshield

To: kitfox-list(at)matronics.com

Date: Thursday, November 11, 2010, 9:08 AM



 --> Kitfox-List message posted by: "egp8111" <egp8111(at)aol.com>



I'm about to replace the windshield on my KF III.  Whats the best way to make long straight cuts in the Lexan ?



thanks,

EG





Read this topic online here:



http://forums.matronics.com/viewtopic.php?p=318964#318964



nbsp;          (And Get Some AWESOME FREE Gif/contribution" rel=nofollow target=_blank>http://www.matronics.com/cont                 -Matt Dralle, Listr?Kitfox-List" rel=nofollow target=_blank>http://www.matronics.com/Navi               - MATRONICS WEB=============





	




         [quote][b]

egp8111

Joined: 25 Mar 2010
Posts: 49

Posted: Thu Nov 11, 2010 10:39 am Post subject: Re: cutting windshield

thanks everyone.  



EG

Float Flyr

Joined: 19 Jul 2006
Posts: 2704
Location: Campbellton, Newfoundland

Posted: Fri Nov 12, 2010 7:00 am Post subject: cutting windshield

I used a spin saw.



First I would put tape over the glass where I was going to cut.  If your

glass still has the protective plastic on it leave it there.  Then I used a

board clamped to the bench at both ends just as a guide for the spin saw.

Take it easy with the spin saw and don't rush. 



When drilling holes I always deburred to prevent cracking through the holes.

I personally tried using a hot welding wire to actually burn holes  so the

edges would heal and increase the strength.. It worked for me but others

have said it didn't work for them.



Noel



--

_________________
Noel Loveys
Kitfox III-A
Aerocet 1100 Floats

Float Flyr

Joined: 19 Jul 2006
Posts: 2704
Location: Campbellton, Newfoundland

Posted: Fri Nov 12, 2010 7:03 am Post subject: cutting windshield

One other point Scott after using your cutoff wheel on plastic it may be a

good idea to reserve that particular wheel for cutting plastics only.  The

rule of thumb I was told with any grinding medium was not to use it on any

metal that doesn't spark.  For instance grinding aluminium causes shards of

aluminium to imbed itself in the wheel where it can heat up causing the

wheel to explode.



Noel



--

_________________
Noel Loveys
Kitfox III-A
Aerocet 1100 Floats

pwmac(at)sisna.com
Guest

Posted: Fri Nov 12, 2010 9:40 am Post subject: cutting windshield

Do you mean the tool that fits in your drill and spins like a drill bit?

PW

======

At 06:56 AM 11/12/2010, you wrote:

[quote]



I used a spin saw.



First I would put tape over the glass where I was going to cut.  If your

glass still has the protective plastic on it leave it there.  Then I used a

board clamped to the bench at both ends just as a guide for the spin saw.

Take it easy with the spin saw and don't rush.



When drilling holes I always deburred to prevent cracking through the holes.

I personally tried using a hot welding wire to actually burn holes  so the

edges would heal and increase the strength.. It worked for me but others

have said it didn't work for them.



Noel



--

Float Flyr

Joined: 19 Jul 2006
Posts: 2704
Location: Campbellton, Newfoundland

Posted: Fri Nov 12, 2010 11:51 am Post subject: cutting windshield

Yes but I use mine in the Dremel (11,000rpm ?)  the spinning action of the

saw blade is self cleaning and makes a very smooth cut without heating up

the plastic.  Without the wood as a guide a straight cut is very difficult

though.



Noel



--

_________________
Noel Loveys
Kitfox III-A
Aerocet 1100 Floats

Roger Lee

Joined: 10 Jan 2006
Posts: 1464
Location: Tucson, Az.

Posted: Fri Nov 12, 2010 2:40 pm Post subject: Re: cutting windshield

The Dremel is certainly a handy tool. I use it all the time. I have used the composite cut off wheel to do plastics, but usually use it on metals. I now use the Dremel blade that looks like a toothed round saw. Like something you might see on a table saw. I have used this blade on several plastic projects and like it better since the other composite cut off blade can sometimes melt the plastic and leave a terrible edge. The round tooth saw blade does not melt the plastic and leaves a nice smooth cut and with the variable speed of the Dremel making a nice edge with this is easy.

_________________
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Tucson, Az.
Rotax Instructor & Rotax IRC
Light Sport Repairman
Home 520-574-1080 TRY HOME FIRST
Cell 520-349-7056

Tommy Walker

Joined: 12 Jan 2006
Posts: 442
Location: Anniston, AL 36207

Posted: Sat Nov 13, 2010 4:58 am Post subject: Re: cutting windshield

Hi,



A trick that the Zenith builders use is an Olfa Knife and a straight edge.  The Olfa is great for cutting thin (.016 - .032) aluminum and plastics like Lexan.  You just have to finish off the cut edge with a file.  I wouldn't be without an Olfa knife, available at Home Depot and other places.

_________________
Tommy Walker
N25A - Anniston, AL

airjunkee

Joined: 08 Nov 2009
Posts: 2
Location: Vancouver Canada

Posted: Sat Nov 13, 2010 7:42 pm Post subject: Re: cutting windshield

Hello



I have found that the best way to make a new windshield is to use the old one as a template. Cut a 4x8 sheet of plywood(1/2 inch) to the desired shape with a combination of circular saw with straight edge and jig shaw for the tight inside curves. Place the new sheet of lexan over the plywood and clamp as required. Use a trim router with a flush cutting bit to cut out the windshield. You will find that the cuts are very smooth and require no additional sanding.  Now save the plywood template, next time a windshield is needed it will take all of 10 minutes to cut another one.



Shawn

PMorel

Joined: 09 Jul 2007
Posts: 62
Location: Locust Grove, GA USA

Posted: Sun Nov 14, 2010 5:22 am Post subject: Re: cutting windshield

I really like the idea of keeping a plywood template.  What I've done to add to the windshield is to mask off about a 1 inch edge along the inside of the windshield and door windows.  Then spray flat black paint in order to give a clean sharp edge.  Looks great!

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Beemer

Joined: 26 Aug 2006
Posts: 87
Location: Middle Georgia

Posted: Tue Nov 30, 2010 6:12 am Post subject: Re: cutting windshield

I used to use a scroll saw to cut mine. It works ok, is fast, can easily accomodate a guide for straight cuts. Then finish off with a belt sander or a router for a rounded edge.



I bought one of those oscillating saws from Sears for a home project. On a whim, I tried it on the Lexan for my windshield. With the saw attachment, it really works great! You could fab a fence for dead-straight cuts, but the tool will follow a line very well without it. 



Beemer

_________________
Beemer
KF2 (and now an M3!)
Suzuki G10 three-banger
Middle Georgia

WurlyBird

Joined: 16 May 2008
Posts: 207
Location: North Pole, Alaska

Posted: Tue Nov 30, 2010 7:15 am Post subject: Re: cutting windshield

Same same. Scroll saw by hand, belt sander for finish, dremel with a sanding disc for curves.

_________________
James
Kitfox 3 / 582 / 70" IVO 2 blade GA
50 hrs on the 582 swapping for HKS 700E and Avid Cowl.

shanesather(at)netkaster.
Guest

Posted: Wed Dec 08, 2010 5:01 pm Post subject: cutting windshield

Just a test as I am not receiving messages

Shane



Do not archive



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