Lexan is a trade name for a polycarbonate plastic that can cover greenhouses or be used as a window replacement. Lexan plastic uses light inhibitors so it won't become brittle in sunlight. The Lexan material generally comes in sheets 4 feet wide by 8 feet long. Thin Lexan less than 1/8-inch thick can be cut with a basic hand shear, but thicker material must be cut using a power tool, typically a circular saw. A special fine-tooth blade must be used to cut Lexan.
Instructions
1. Install the carbide blade on the circular saw according to the saw manufacturer's directions. The blade must have at least 60 teeth; the more teeth the blade has, the finer the cut through the Lexan will be.
2. Set the sawhorses approximately 7 feet apart. Lay the two two-by-fours across the sawhorses to form a cutting platform for the Lexan sheet.
3. Lay the Lexan sheet across the two-by-fours. Be sure the boards support the entire length and width of the plastic sheet.
4. Measure the size of the cut you want to make, using the tape measure. Transfer any identifying marks to the sheet with a grease pencil. The grease pencil can be cleaned off the Lexan surface much more easily than a black permanent marker.
5. Slide the two-by-fours under the sheet material so the boards will not interfere with the cutting blade of the circular saw.
6. Set the depth of the cutting blade on the circular saw 1/16 inch greater than the thickness of the Lexan sheet material. For instance, if the Lexan is 1/4-inch thick, set the blade depth for 5/16 inches.
7. Cut the material in one smooth push of the circular saw. Do not start and stop the saw in the Lexan because it can cause the edges of the plastic material to melt.
Tips Warnings
Curves may be cut in the Lexan sheet material using an electric jigsaw. The blade must have 10 teeth per inch. Use the same setup with the sawhorses and two-by-fours. Arrange the boards so they will not interfere with the jigsaw blade.
Wear safety glasses when cutting any material with a circular saw. The saw blade will cause material to become air borne.
Follow all safety instructions listed by the circular saw manufacturer.
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