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How to cut Plexiglass
There is a big difference between Lexan and plexiglass. Plexiglass breaks very easily particularly in thinner sections. Around 1/8" thick Plexiglass may fracture while you are trying to saw or drill.
Most windshields that I've seen on ATV and RTV's have been made from 1/8" thick Lexan. Lexan is more expensive but will last, particularly with bumps, jarring and vibration from your application. Like Earthworks says, boy 1/2" thick is heavy!
Lexan can be drilled and sawn easily. In more static situations we even tap it at times for machine guards, etc.
All of the above scratch easily so care should be taken when cleaning to not rub dirt in. Some glass cleaners also shouldn't be used. Read directions of cleaners first before applying.
When sawing you want very fine teeth and don't push it hard. I also like to mount them using rubber grommets so you don't stress crack it. Stay in a ways from edges. If you can't find grommets locally, like your hardware store, etc. go to McMaster-Carr (mcmaster.com).
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How to cut Plexiglass
Yooperpete , How do you tell difference between Lexan and plexiglass, thanks
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How to cut Plexiglass
When you purchase either of them, they should have a paper or plastic skin on them to prevent scratches in handling. It should say what it is.
After you do your cutting, etc. you peel it off.
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How to cut Plexiglass
I realize the question was cutting it, but in talking with an air conditioning contractor a few years ago he said you can bend lexan using a sheet metal brake. He did have some he used for air deflectors.
If you are really worried about cutting it, you can clamp a piece of wood on top of it to reduce vibration. Keeping it tight to saw surface seems to be the biggest issue for me.
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How to cut Plexiglass
Terry: Lexan visually and generally speaking has a blueish or light grayish hue or tint to it, unlike the acrylics (Plexiglass is a brand) which are more clear. Acrylics generally are harder to the touch and harder to scratch (depending on the tool) or item used. Lexan tends to be more flexible and much softer but is easily scratched---even a clean finger wiped across it will scratch it. Each when burned have a certain odor. Polycarbonate is another "plexiglass"-type material. It degrades rapidly in sunlight quicker, and in some cases turns into powder when exposed to sunlight and/or heat. Poly scratches easily too, is hard to work with, and can be brittle. Poly is very hard to burn, unlike acrylics. Poly is used in welding helmets light shields for its resistance to weld spatter. It will accept a hot spatter without melting. Some watch face crystals and eyewear lenses are made of poly---and you'll know it--if you put alcohol or other solvent on them they will turn into a chalky mess.
Kenny: If the AC guy did use a sheetmetal brake chances are he applied heat from a propane torch to the edge. Otherwise, it would have cracked or went back to it's original form of being flat. Some of the newer engineered vynils used for house trim do retain their shape when formed/bent. Some of the styrenes and expanded styrenes can be bent without heat but they tend to fracture and can break. ABS is a type of styrene and is very hard to bend with out it cracking. Heat applied to the bend works well.
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How to cut Plexiglass
We bend Lexan at our shop frequently using a brake. You don't need to heat it if you are doing a 45 or 90 degree bend. When room temperature you only get one shot at it and need to slightly go beyond the angle since it has some springback. You can't roll it to make a curved surface or bend a large radius in it at the bend. Sometimes it does break for no apparent reason. Heat may help you do some more exotic bends, etc. - haven't tried it myself.
Yes it is soft. Lexan like Plexiglass are tradenames. Lexan is commonly the material used on Bug Shields and have lots of give and flex capabilities even in a broad temperature range. You do need to smooth all corners and edges to avoid a place for a crack to start.
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