Pelican Parts Forums - Plexiglass/acrylic cutting shaping

This weekend I installed a new plexi windshield in my boat. I thought I would share for those of you who may need or want to cut Plexi. I am sure this will work just as well on Lexan/Polycarbonate. Plexi has a reputation for being difficult to cut as it chips and cracks easily. For the DIY'er the typical method of cutting is with a hacksaw (deadly slow) or a plywood blade in a circular saw backward but you still run the risk of cracking the piece. Last year I bought the cheap Harbor Freight multi tool to scrape the glued down carpet and contact adhesive on vinyl wall paper from the walls and floors of my boat. The tool came with a "half moon" blade intended to cut copper and aluminum. The blade is bi-directional and does not have an offset. I test cut the plexi on what would be a cut off of the new piece. It worked flawlessly. I used the old windshield as a pattern and traced it. I then took the tool and made one slow pass to create a groove to follow. After about four or five passes the new windshield was cut. I needed to refine the shape and was able to shave slivers of plexi off until I got to my desired shape. The tool and blade worked perfect not a single chip, scratch or crack. The plexi I cut was 3/8" thick. I think if you want to cut car windows it would be easier and quicker. If the glass company were to cut the plexi to shape the cost would have been $350.00 I bought the blank for $120.00. Not bad considering the tool cost $40.00.

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