Best tool for hand cutting acrylic or polycarbonate boat windows

[Lakesailor]

Why not get it cut by the supplier? He pays for rejects then.

 

[Pete54]

I replaced the canopy of an aicraft - Lexan material and we used a dremel type tool. Very controllable and gives a clean edge once sanded. The material we used was fairly thin (cruica 3mm) and so a tool like a jigsaw would have caused cracking. Probably OK on the thicker material used in windows but the lack of vibration and easy of control made trimming very easy.

 

[rob2]

My friend and I got good results with a jigsaw - cut slow and gently to allow the heat to dissipate. Straight edges we smartened up with the belt sander and then hand sanded to finish. We did a few experiments with smoothing/polishing the edges of some scraps with a hot iron, which gave a great "fresh cast" finish but was difficult to control and very slow.

Rob.

 

[prv]

Why not get it cut by the supplier? He pays for rejects then.

In my case, because I needed to use the old washboards as a template to cut the new ones. I can't imagine most suppliers being interested in cutting irregular shapes, but even if they were, I wouldn't want to be without the boards while they did the job.

Pete

 

[Rick_A]

Does nobody use a grinder to cut the perspex? Very quick and easy.

 

[bikerbill]

Does nobody use a grinder to cut the perspex? Very quick and easy.

Yup, used an angle grinder to cut 6mm Perspex to use as windows for the garage. Leaves a bit of a mess though

 

[Mark G]

I prefer do it by hand!

I use a hand saw and and long flat file to clean the edge. It's actually very quick.

For exposed edges very fine wet and dry produces a surface that is pretty well transparent.

I also prefer to use a hand saw - (a Stanley "Jetcut" with fine sharp blade works well) - produces a much straighter edge than a jig saw, unless you use a guide.

For getting the edges dead straight, I stick the abrasive, the stuff that comes on a roll, onto a piece of 1 inch square timber about a foot long and use plenty of elbow grease.

 

[Slocumotion]

Confirmed then -
a hand job gives the best finish.

 

[prv]

produces a much straighter edge than a jig saw, unless you use a guide.

That seems a little like saying "bananas are really tough and stringy to eat - unless you peel the skin off first"

Obviously, if trying to cut a straight line with a handheld tool, one would be using a straight-edge clamped in place as a guide.

Pete

 

[lancerno1]

To prevent acrylic heating and welding back together when cutting with a jigsaw etc. It is a good idea to cover the cut line with masking tape, draw the cut line on the tape.