AIRPLANE PLASTICS 1-937-669-2677
1. Cutting: An abrasive disc powered by a high speed drill, a Dremel tool, or a die grinder recommended. We have found that abrasive cut-off wheels or aluminum oxide or silicon .. carbide provide excellent cutting results. A three inch disc is available at most hardware stores for around $3.50. A small grinding disc or Dremel saw disc will also give good results. Reciprocating saws like saber saws are not recommended and will probably break your canopy. A tool that progresses slow and hot to grind through the canopy is best. Tape a poly plastic cover on the canopy and mark your outline with a grease pencil. Never cut a cold canopy! Allow the canopy to warm to 70° or more for at least an hour. Don't allow the canopy to vibrate or chatter during the cutting or it may chip and crack. Support your canopy on a flat surface so it will not twist or spread during the trimming. Duct tape is handy to hold things in place. Remember: cut slowly, don't push the cutter. Let the tool do the work. Be sure to use eye protection. Plexiglas chips can be a problem in your eyes since they are clear and difficult to see. After the canopy is trimmed, use a hand held belt sander to sand down to your line. Deburr edge with a scraper or sandpaper before trial fitting to keep from breaking canopy or cutting fingers.
2. Drilling: The drill should be ground off to a zero rake angle to prevent digging in, chipping and cracking the Plexiglas. A standard drill bit, ground with no cutting edge pitch, IS a safe method of making holes. Be sure to make the holes 1/8" oversize to allow for motion caused by thermal expansion and contraction. De-burr hole with countersink. Use elastic stop nuts and tighten until you can see reflection around screw bend and back screw off 1/2 turn.
3. Cleaning: A damp soft cloth or an air blast will clean the saw dust away. The damp cloth will also dissipate static electricity. To clean dirty plexiglass use plenty of water and a non-abrasive soap or detergent. Dry with a clean chamois or soft cloth. Never use acetone, benzene, carbon tetrachloride, lighter fluid, lacquer thinners, leaded gasoline, window sprays or scouring components. Grease or oil may be removed with kerosene, white gasoline, naptha or isopropyl alcohol. Small scratches can be buffed out with "Mirror Glaze HGH-17 and lots of rubbing. Hard automobile paste wax should be applied as a protective coating and buffed with a soft cotton flannel cloth. Do not use cheesecloth, muslin or shop cloths, they scratch. For deep scratch removal, procure a micro mesh kit from a plastic sheet dealer or your canopy supplier.