I did cut some polycarbonate yesterday.
An oscillating saw works well for curves. You cut several times from both sides until you are through.
An angle grinder with a thin cutting disk for stainless works as well.
Small radiuses in the corner can be achieved with a coarse grinding disk.
Just remove the melted plastic regularly.
I had a small crack and drilled at its end with a Dremel a small hole to stop it from further cracking. Used the combination drill router bit for it.
The holes can be filled in with epoxy
, especially when the epoxy
is hidden by the black UV protection described next. If not epoxy yellows with UV.
We decided to forgo any mechanical fasteners and external frames in the future and structurally bond entirely with Sika 295UV.
Usually mechanical fasteners are where it cracks. Oversized holes are a must if you use mechanical fasteners.
The most important is to use their 209 black primer on the window gluing surface and (crucial!!) protect the gluing surface also from UV by painting a black cover strip onto the window outside where it's glued.
Alternatively use a black UV protection tape on the outside.
Sika has a very good manual for this.
That way the window will glue very well and last longterm.
Just got of the phone
talking to the Sikaflex technical department. They confirmed the absolute necessity of using the external UV protection as well.