87lc2 2666 Posted February 15, 2021 Wondering if anyone has any easy tricks for cutting out panels in lexan/polycarb bodies. Not talking about cutting/trimming the body or reaming post holes, talking about cutting sections out (windows, truck beds, etc). I currently use a variety of methods (Xacto blade, Dremel cutting bits, etc), but it's one of my least favorite things to do and wondering if there's a tool I don't know about that makes this easier. Share this post Link to post Share on other sites
Fuijo 880 Posted February 16, 2021 I would make a daisy-chain of holes close to the edge around the panel to be cut out with a reamer, and then use a file for the rest. Slow, but guarantees no mistakes. 1 Share this post Link to post Share on other sites
Mrowka 495 Posted February 16, 2021 I cut small holes in the corners, and then "connect the dots" with an X-Acto knife. Sometimes, I cut away the center part first if it is a larger panel. 1 1 Share this post Link to post Share on other sites
87lc2 2666 Posted February 16, 2021 7 minutes ago, Mrowka said: I cut small holes in the corners, and then "connect the dots" with an X-Acto knife. Sometimes, I cut away the center part first if it is a larger panel. Yes, I have tried this method and it does work well. Only gives me trouble on thicker bodies where it's hard to cut through the lexan. A lot of my truck bodies are really thick and a real pain to cut. On thin bodies this works great. I was thinking there was a tool out there that I was unaware of that would make this really simple, but looks like it just takes some time and patience. Share this post Link to post Share on other sites
Mrowka 495 Posted February 16, 2021 I do the score and break method. Seems to work so far. Clean up edges with a nail file or Dremel. Share this post Link to post Share on other sites