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Major Softie wrote:Moosehead, he wasn't actually suggesting you use a standard grinding wheel, but a "cutting disc" ON a grinder. Those cutting discs are only about 1/16" thick. I still prefer the jigsaw, as the grinder is harder to control, but it's not quite as coarse a tool as you imagine if you use one of those cutting discs.

Yep, figured he was referring to the thin cutoff wheels .... but my angle grinder weighs about 10lbs and fiqured a dremel would be a hell of a lot easier to control. And besides one of the boys has "borowed" the variable speed jig saw I guess "cause can't find it anywhere....arrrraaaaugh...love it when they drop in/visit but I never know what gets "borrowed" until I need it!

Use a coping saw with a fine tooth blade and do it by hand. Nice and slow
Tape up both sides with blue painters tape

When I cut my screen down, I used a cheese grater file for some shaping, and it worked well. My suggestion would be to cut above your line, then use the cheese grater file to work down to the line. If you want, you can practice with the cheese grater file on the portion of the screen you are going to cut off.

We make racecar windshields with a jigsaw and a fine blade. The damage will not come from the blade but from the sole of the saw bouncing on the plexi, so tape everything up well. During the filing, sanding part, you can also get a final edge finish either by dragging a sharp knife at 90* or by hitting the edge quickly with a small flame from a propane torch.

Please note that you can do pretty much what you want heat-wise to plexi, but Lexan will outgas with too much heat, leaving you with tiny bubbles trapped in your work.

SteveD wrote:I marked the screen and used a hacksaw with a new blade. Easy as long as you remain careful and patient.

+1 using a blade for scroll cuts

While I had settled on using the dremel w/cutoff wheel, the varible speed jigsaw showed up at a friends cottage I was doing some reno work on for him (and I blamed the boys for "borrowing" it...sorry guys). So the plan is the jig saw route. Got a nice fine toothed metal blade and will give her a go. Get it taped up well, steal a few pillows and lay it down and have go at it. Quicker this way.

Trouble is, we just got a nice dump (10cm) of the white stuff last nite so don't feel the urgency I did a few days ago to get this done. But then again, be ready for the early spring riding!

I taped both sides and used a vertical band saw with the fence set to amount to be removed and feed slowly. Set saw speed slow and do not get in a rush.
Guy