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Author Topic:   Working with Plexiglas

R T M posted 07-03-2009 08:22 AM ET (US)
Very simple material to work with. The first 3 pics are of the finished piece (it will keep water from spilling over the transom of my raceboat. I used .20 gauge Plexiglas.
http://i27.photobucket.com/albums/c191/floridaboy2053/plexiglass/ 100_1066.jpg
http://i27.photobucket.com/albums/c191/floridaboy2053/plexiglass/ 100_1069.jpg
http://i27.photobucket.com/albums/c191/floridaboy2053/plexiglass/ 100_1069.jpg
Becuase of the many angles I had to make a mold or a form to clamp the plexiglass into as I heated the bend points one at a time.
http://i27.photobucket.com/albums/c191/floridaboy2053/plexiglass/ 100_1053.jpg
first I made a cardboard pattern, and then cut the plexiglass to the pattern
http://i27.photobucket.com/albums/c191/floridaboy2053/plexiglass/ 100_1054.jpg
http://i27.photobucket.com/albums/c191/floridaboy2053/plexiglass/ plexiglass-1.jpg
Then I finished the edges, first with a belt sander, then with an orbital sander, and then hand sanded with some
1000 grit so the edges becomes translucent. After this, I marked the bends on the glass with a marking pen, using the cardboard pattern, and simply laid the bend point over the edge of a board and heated it with a heat gun on high. You must move the gun rapidly back and forth, and on a small piece like this, the glass will fold over by itself in about 3-4 minutes. When the glass falls over it is very pliable for about 2 minutes, and I just clamped it into the mold and let it cool. If you are making a simple windshield with 90 degree bends, no mold is needed, just heat it in the same manner, and it will bend over, all by itself, don`t try forcing it. If you start with a level table to bend it It will fall to 90 degrees. After it falls over, lay a wet cloth over it so seal in the bend. It is very simple to do, and work with. Don`t overheat as tiny bubbles will form in the glass.
http://i27.photobucket.com/albums/c191/floridaboy2053/plexiglass/ 100_1063.jpg
http://i27.photobucket.com/albums/c191/floridaboy2053/plexiglass/ 100_1060.jpg
rich/Binkie

R T M posted 07-03-2009 08:31 AM ET (US)
Here is the plexiglas clamped in the mold
http://i27.photobucket.com/albums/c191/floridaboy2053/plexiglass/ 100_1061.jpg
Another pic of the plexiglas installed
http://i27.photobucket.com/albums/c191/floridaboy2053/plexiglass/ 100_1070.jpg
rich/Binkie
alfa posted 07-03-2009 12:14 PM ET (US)
Nice article Rich. Thanks for sharing.
Alain
high sierra posted 07-03-2009 05:02 PM ET (US)
Very well done. high sierra
Newtauk1 posted 07-03-2009 09:48 PM ET (US)
Wow. You make it look easy. I imagine there are plenty of projects that could incorporate your process. Thanks for sharing.
PeteB88 posted 07-04-2009 11:30 PM ET (US)
Rich - How do you cut the stuff? I tried to cut a piece today (trim actually) w/ sabre saw and it kept melting back and sealing the cut like plasma or something. What's the trick?
Pete
alfa posted 07-05-2009 01:48 AM ET (US)
Put adhesive tape under the plexiglass before cutting.
my 0.02
R T M posted 07-05-2009 07:14 AM ET (US)
Pete,
R T M posted 07-05-2009 07:41 AM ET (US)
Sorry, this computer has a hair trigger.
Use a blade that's meant to cut plastics. Also, use alfa`s idea. tape on both sides. You will get a little chipping, but no matter. Clamp your belt sander in a vice and run the edges over it Use 60 grit belt. Then slightly bevel the edges to finish it and get rid of the chips with your orbital sander and 120 paper. Then rub down the edges with some 1000 paper, dry. Don`t touch the flat surfaces with sandpaper, or its curtains. It may be possible that the blade you are using may be too fine if it is melting the plastic. The blade I used was a Bosch T123X3 from Home Depot. You may not have a Bosch saw, but look at the blades to get an idea of the size of the teeth. I`m trying to figure out how to make a curved windshield for my '59 tail fin boat. I`ll try to make a mold out of thin Masonite or counter top grade Formica and lay the glass over it and heat it and see if it will lay down over the mold. I`ll try a small piece first. The windshield will be about 5 feet long. Any used ones I find are not in great shape and are expensive. Working with Plexiglas is easy and kind of fun in a way.
rich/Binkie

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Author	Topic: Working with Plexiglas
R T M	posted 07-03-2009 08:22 AM ET (US) Very simple material to work with. The first 3 pics are of the finished piece (it will keep water from spilling over the transom of my raceboat. I used .20 gauge Plexiglas. http://i27.photobucket.com/albums/c191/floridaboy2053/plexiglass/ 100_1066.jpg http://i27.photobucket.com/albums/c191/floridaboy2053/plexiglass/ 100_1069.jpg http://i27.photobucket.com/albums/c191/floridaboy2053/plexiglass/ 100_1069.jpg Becuase of the many angles I had to make a mold or a form to clamp the plexiglass into as I heated the bend points one at a time. http://i27.photobucket.com/albums/c191/floridaboy2053/plexiglass/ 100_1053.jpg first I made a cardboard pattern, and then cut the plexiglass to the pattern http://i27.photobucket.com/albums/c191/floridaboy2053/plexiglass/ 100_1054.jpg http://i27.photobucket.com/albums/c191/floridaboy2053/plexiglass/ plexiglass-1.jpg Then I finished the edges, first with a belt sander, then with an orbital sander, and then hand sanded with some 1000 grit so the edges becomes translucent. After this, I marked the bends on the glass with a marking pen, using the cardboard pattern, and simply laid the bend point over the edge of a board and heated it with a heat gun on high. You must move the gun rapidly back and forth, and on a small piece like this, the glass will fold over by itself in about 3-4 minutes. When the glass falls over it is very pliable for about 2 minutes, and I just clamped it into the mold and let it cool. If you are making a simple windshield with 90 degree bends, no mold is needed, just heat it in the same manner, and it will bend over, all by itself, don`t try forcing it. If you start with a level table to bend it It will fall to 90 degrees. After it falls over, lay a wet cloth over it so seal in the bend. It is very simple to do, and work with. Don`t overheat as tiny bubbles will form in the glass. http://i27.photobucket.com/albums/c191/floridaboy2053/plexiglass/ 100_1063.jpg http://i27.photobucket.com/albums/c191/floridaboy2053/plexiglass/ 100_1060.jpg rich/Binkie
R T M	posted 07-03-2009 08:31 AM ET (US) Here is the plexiglas clamped in the mold http://i27.photobucket.com/albums/c191/floridaboy2053/plexiglass/ 100_1061.jpg Another pic of the plexiglas installed http://i27.photobucket.com/albums/c191/floridaboy2053/plexiglass/ 100_1070.jpg rich/Binkie
alfa	posted 07-03-2009 12:14 PM ET (US) Nice article Rich. Thanks for sharing. Alain
high sierra	posted 07-03-2009 05:02 PM ET (US) Very well done. high sierra
Newtauk1	posted 07-03-2009 09:48 PM ET (US) Wow. You make it look easy. I imagine there are plenty of projects that could incorporate your process. Thanks for sharing.
PeteB88	posted 07-04-2009 11:30 PM ET (US) Rich - How do you cut the stuff? I tried to cut a piece today (trim actually) w/ sabre saw and it kept melting back and sealing the cut like plasma or something. What's the trick? Pete
alfa	posted 07-05-2009 01:48 AM ET (US) Put adhesive tape under the plexiglass before cutting. my 0.02
R T M	posted 07-05-2009 07:14 AM ET (US) Pete,
R T M	posted 07-05-2009 07:41 AM ET (US) Sorry, this computer has a hair trigger. Use a blade that's meant to cut plastics. Also, use alfa`s idea. tape on both sides. You will get a little chipping, but no matter. Clamp your belt sander in a vice and run the edges over it Use 60 grit belt. Then slightly bevel the edges to finish it and get rid of the chips with your orbital sander and 120 paper. Then rub down the edges with some 1000 paper, dry. Don`t touch the flat surfaces with sandpaper, or its curtains. It may be possible that the blade you are using may be too fine if it is melting the plastic. The blade I used was a Bosch T123X3 from Home Depot. You may not have a Bosch saw, but look at the blades to get an idea of the size of the teeth. I`m trying to figure out how to make a curved windshield for my '59 tail fin boat. I`ll try to make a mold out of thin Masonite or counter top grade Formica and lay the glass over it and heat it and see if it will lay down over the mold. I`ll try a small piece first. The windshield will be about 5 feet long. Any used ones I find are not in great shape and are expensive. Working with Plexiglas is easy and kind of fun in a way. rich/Binkie