Cutting plastic panels

[daaboots]

You guys have any tricks for cutting the plastic (HDPE) panels and keeping a nice straight edge? Please don't suggest water or lazer cutting cause I don't have one of those machines - yet

[Kuma]

you could try a circular saw, use something for a straight edge to run the saw against to hold a straight line, the trick will be to have a nice sharp blade to generate as little heat as possible, you will probable still need to run a file along the edge to knock the bur off.

[plkracer]

Can you score it and crack it off? I haven't used hdpe panels, but at work we used haircell abs sheets, and we cut into it maybe a millimeter, and it would break nicely. A little touch up with a DA and you are done.

I'm thinking polyethylene will be a little soft/tough for this to work though.

[MASCMAN]

I cut my Harley windshield with a jigsaw, then sanded it followed by a quick swipe with a torch to get that white look out of the plastic...don't know how similar the two materials are though.

[Bullnerd]

Sharp woodworking tools will work.

Those little hand held de-burring tools (noga style) work good, buy don't let it dig in.

[BorntoBraaap]

I like that tip about touching the edges lightly with a torch. Thanks, Ill be using that.

[Bullnerd]

I don't think the windscreen is hdpe.

Probably acrylic (plexiglass) or polycarb.(poor mans lexan)

Torch will work on acrylic , not sure about polycarb, don't think you'd need to on hdpe.

[MASCMAN]

I'd say if it turns white then try it...heat gun works too.

[bazz]

I don't think the windscreen is hdpe.

Probably acrylic (plexiglass) or polycarb.(poor mans lexan)

Torch will work on acrylic , not sure about polycarb, don't think you'd need to on hdpe.

Hey Bull,Lexan is polycarb,it's just a tradename.

[plkracer]

They do make differential grades as well. We buy makrolon fairly often, and they make really hard grades that are as tough as polycarbonate but hard like acrylic. They also make laminated sheets that have different properties.


Boots, how thick are your panels? Ever looked at using a linoleum knife with a straight edge?