Trimming headlight covers

[Darrin]

I got a set of headlight covers (RCRs, very nice BTW) that are slightly oversize for my cutouts. How do you go about trimming the plexiglass to fit just right?

 

[Julian]

I'm in the process of installing all new plexiglass on my KVA, I have no idea how others are doing it but I found an air powered body saw to be best to get a close outline and then finishing with a surform.

Julian

 

[Jim Cowden]

I used a small wood plane.

Jim

 

[mahlon]

If we are cutting Lexan a good pair of sheet metal or tin snips have worked good for us as long as the material isn't more than aroxx. 120.th thick. When I do plexi I use an air saw to get close ,and then a high speed 36 grit small sander/grinder with final finish sanding as the plexi is much more brittle.............m

 

[Jack]

For small fitting cuts, 36 grit on a block, finer grits to finish, and a quick polish of the edges.

 

[Darrin]

Dremel with cutoff blade and then 60grit on my Porter Cable hand sander did the trick and I think this is Lexan as it is very pliable. Tough stuff by the looks of it. Pretty thick.

 

[Fred W Ballinger]

If you have quite a bit to take off I've had good results dressing the edge on a bench belt sander. If you don't have one you can grip a handheld version upside down in a vice. Then you can hold the part in both hands and squat or kneel down to get a good view of what you are doing. Mark where you need to trim with with felt tip pen so you can see not to take too much off.

Cheers

Fred W B

 

[Mark Maybury]

I also use a large 6" X 48" belt sander but I remove the table and lay the belt horizontal and sand inline with the plexi glass at a slight taper.
Remember sand a little and check often as these machines remove a lot of material in a hurry.
The other method I use is a jointer but you need to be even more careful not to chip the edges as I broke my spare rear window with the jointer with just one slip.
Regards,
Mark