whats the best tool for cutting lexan? what kind of blades do you use? i wanna use a jigsaw so i have better control over it. thanks in advance for any advice.

 

Use a jigsaw with a fine toothed blade in it. Be sure to mask off the lexan where the base plate of the saw will be riding though...or youll have TONS fo scratches! Good luck!

 

Go to a place that sells lexan to sign companies and they will have blades made for cutting it. If I recall correctly, they are fine-toothed with little or no offset.

Best of luck in your project.

 

If you want it to be perfect and I mean perfect you want to use a laminate trimmer. The same thing they use to finish counter tops. You make a pattern out of wood then you lay the lexan on top of the wood and use a flush trim bit to trace the wood pattern. Not only will it come out perfect it will only take you a matter of seconds to reproduce another window that is exactly the same. If you take your time they will look like this.

Good luck

 

Fine tooth blade in a jigsaw, and tape both sides of the cut. Don't force the blade forward, let it do its work, or you'll melt the plastic.