Polycarb Windows

[skinner2k3 3]

I know someone in the glazing buisness who can get me a sheet of 4mm solid polycarb for cost price and seeing as I have already lost money to that thieving little **** I thought it may be worth making my own to keep costs down.

 

I assume I am going to need a 8'x4' sheet to do all side and the rear windows?

 

Is there any advice anyone who has done this before can give me, ie cutting methods etc?

 

I have used the rear rubbers to make a template, intend to draw around the fronts and trace the rear onto a large sheet of paper before attempting to remove it and obviously ending up breaking it into thousands of pieces.

 

Alternatively has anyone found from experience that its actually a huge pain in the arse and cost almost as much as set of ready made ones once you have bough all the tools, sliders etc?

 

Cheers

 

Ben

[Miles 331 1 Cars]

When I've seen it done the tool used was a Jigsaw, simple as that but watch out of some Polycarb can crack very Easily, Slider's can be bought from Demon Thevies or I guess Rally Design at about 3/4 of the price

[Tom Fenton 1,541]

Use a jigsaw to cut it, you can then use a small block plane (carpentry tool) to smooth and shape the edges.

[skinner2k3 3]

Cheers chaps. Jigsaw it is.

 

Will 8'x4' be enough?

[mbayley77 0]

Make sure that you put some cloth or similar on the bottom of the jigsaw between the poli as I found my jigsaw scratched the poli pretty bad.

 

As a hand finish for the edges use a file sideways across the edge, then use wet and dry to finish to a nice smooth edge. this should help stop any cracking occurring in the future from "chips" etc.

[SPGTi 2]

I did my own rear 1/4s. I used base model, non opening windows as the template and the base model non opening rubbers to fit them. I used a good hand saw, find it easier than a jigsaw and the cut is better.

 

Steve