Cutting polycarbonate windows

[sniff petrol]

What's the best way? Bought some 3mm sheets to replace the windows on my 205 GTi trackcar.

Thanks.

[eccles]

I was using a bandsaw and a jigsaw to cut some polycarbonate last week (for a triumph stag windbreak behind its seats), and these cut it quite nicely. finished off with a rough file, all sorted.

[sniff petrol]

eccles said:

I was using a bandsaw and a jigsaw to cut some polycarbonate last week (for a triumph stag windbreak behind its seats), and these cut it quite nicely. finished off with a rough file, all sorted.

Ok, I've got a jigsaw with an assortment of blades - suppose the smallest teeth are best?

Just wanted to check before cracking it.

[optimax sniffer]

Not sure about the blades but I guess finest is best. Let the blade do the work rather than forcing it through the material. On the other hand don't hang around to long as you could end up melting the surrounding material and it re-welds itself behind the blade. Only had that problem on 10mm sheet or above though.

[thunderbelmont]

I've just cut a front and rear screen out of a sheet of Makrolon (a clever polycarbonate with a hard anti-scratch facing), and I used my bestest jiggerysaw with a fine-toothed metal/plastics blade. Don't run the saw with too much "attack" on the cutting stroke (if yours is adjustable), and take your time.

Finish with fine file, or a little wet'n'dry. If you find they're a little big and need a fag paper taken off, I use a 4.5" angle grinder with a sanding disk/pad to gently "adjust" the edges.