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[U-33]

Chaps, any ideas to how I cut a Lexan body shell? Do I use scissors, sharp scalpel, or what?


I have to remove the section shown in order to fit the header pipes, but the Lexan is like me nowadays...all floppy. 

[Shipmate60]

Anything sharp that you are happy to use.
Bob

[grasshopper]

if you want to be really accurate, lexan scissors or a sharp knife.


Assuming the body is un-painted,


For general racing body shells I score along the cut line and fold back, lexan will split along the line, inside curves I tend to cut on the waste side of the line as best I can and use a rotary sander in a 'dremel' to sand back to the correct line.
Clean with warm soapy water, shake and dab dry with paper towel - paint.


If you're just removing a section on a flattish surface, hold body shell over the corner of your bench and use a sharp blade - I find a few light cuts are usually better than a heavy single one, err on the side of caution, cut close to then sand back.


If the shell is already painted I would cut through from the painted side...that would help stop the exisiting paint from peeling back (guess how I discover that!)

[U-33]

Thanks gents...and most informative, Grasshopper...it'll be easier to cut from the outside I think, so I'll probably go for the sharp scissors with a curved blade(nail scissors?)




Cheers guys,




Rich

[essex2visuvesi]

so I'll probably go for the sharp scissors with a curved blade(nail scissors?)

Exactly what I use for cutting out the wheel arches on lexan bodies.... Reminds me I have an Audi Quattro to do for the stepsons RC car

[justboatonic]

Used to cut a lot of these when we used to go RC touring car racing.

Dont cut lexan with a sharp knife on a car body. It never works well and you end up creasing the lexan. Use the curved ended nail scissors. For wheel arches, the curved scissors work well. Alternatively, you can buy a compass like device which takes a scapel blade and is supposed to be good for wheel arches.

[U-33]

Next question...how do I drill holes in Lexan? I need to drill/cut/whatever two 1/2" holes in the window areas for ventilation, and drills seem to fail miserably...

[justboatonic]

Next question...how do I drill holes in Lexan? I need to drill/cut/whatever two 1/2" holes in the window areas for ventilation, and drills seem to fail miserably...

Yep, used to do this to get some cooling air flow over the motor although not half inch holes!

Obviously you need sharp drills. Then what I used to do was hold a solid small block of wood on the inside of the screen and then drill through stepping up drill sizes as you go. With practice, you can hold the lexan shell as well to stop it spinning. Otherwise, get a helper to hold the shell.

If you have good, sharp drills, you can actually drill the screen while fixed to the car chassis although cannot press too hard otherwise the shell will bend.

[essex2visuvesi]

best way i found is to use the tapered sander for a dremel* gets it very neat


*other minidrills from other manufacturers are available

[tattooed]

use a WOOD drill rich as an ordanary drill can rip the lexen

[U-33]

Thanks chaps...Andy, I wouldn't have thought of using a wood drill. Nice one, that..




The ventilation holes aren't for the motor, they are cut into into the side windows to allow the driver access to fresh air, and also to help clear the tyre smoke and nitro fumes that build up.




Rich

[grasshopper]

You can buy tapered, very sharp body reamers for lexan ( and other materials)....useful tool to have in your toolbox.