Thursday
Today I had work that was unrelated to the build, but afterwards I set to and cut the drivers window and both quarter lights out of my lexan sheet.
I did a lot of measuring first, and had enough lexan to make three windows, and both quarter lights so I had room for error, or, if I was good, a spare window!
I also did a lot of research on the best ways to cut lexan, and decided to go the jigsaw tungsten-carbide route.
tungsten- carbide blades are a fairly new thing to me, I wanted some jigsaw metal cutting blades recent;ly, and ordered some tungsten carbide ones, kind of by mistake.
Well they arrived and have no teeth, just a flat blade with the "cutting edge"
tipped with tungsten-carbide. I used them on metal, and they were not much good, but on lexan, WOW terrific, I would never use anything else now.
I was dreading cutting the lexan, but with these blades, it was a doddle.
It does not so much "cut" as "grind" its way through, a bit like a 1mm cutting
disc, but with a reciprocation motion.
Makes the cutting work really easy, and a job to look forward to instead of dreading!
Like most other builders on this forum, my body shell has its anomalies,
because I made my windscreen surround, the left window is half an inch lower at the top than the drivers one.
And when I measured the passengers door, using the drivers side cardboard pattern, it turned out that the left door is one inch shorter for and aft, than the drivers one!
It really is as well that we don't see both sides of the car at once!
I don't even think a concours judge would spot that one.
[IMG]

[/IMG]
[IMG]

[/IMG]
[IMG]

[/IMG]
[IMG]

[/IMG]