What kind of jig saw blade to use to cut plexiglass or another cutting method

[square1]

There is an inexpensive knife with a special cutting edge just for plastics. They work well, one or two passes and snap it on the scored line. A hollow ground planer blade in a table saw also works well.

 

[PILOON]

I have found that major lumber yards and big box stores generally carry plexiglass so I'd try them.

If not 'on hand' they probably can order, generally the would offer 2 x 4, 4 x 4 or full sheet.

 

[dragoneggs]

I didn't read whether you were cutting straight lines or how thick the plastic is but... for a clean straight and square edge, I leave the peel ply on and use a table saw with lots of teeth (80 or more for 10in blade with carbon teeth having a very low or even negative rake. This works very well especially when cutting thick material up to 1/2in or more. The edges if needed, can then be progressively sanded with finer and finer sandpaper getting it to a glass appearance if necessary (4000+ grit). Yes very easy to melt if blade is not sharp, speed to slow.

 

[EddieWalker]

I gave up trying to make my own and just bought a pre-made Lexan windshield for my RTV for $300 shipped. Not only were prices for raw material crazy in the size I needed, but the nice clamps to hook the windshield to the roll bar were going to cost about $15 a pop (I didn't want to use conduit straps or pipe clamps since it looks pretty cheesy). For just a little bit more I was able to get a nice Lexan windshield that had been perfectly shaped to fit the RTV, and had smooth/clear edges, much better than I could have done.

If you do make your own, be sure to use Lexan, not plexiglass, since it is a lot tougher, optically clearer, more scratch resistant, and more crack resistant. To me, plexiglass on a UTV is just ripe for scratching and cracking due to the vibrations and typical usage. And I'd recommend oversizing the attachment holes and use rubber grommets in them with loose fasteners to avoid putting direct pressure on the material and allow room for expansion (plexiglass and Lexan will want to expand in the heat and contract in the cold, and that can cause warping/cracking if the material is rigidly mounted). Can use nylon locking nuts on 1/4-20 bolts through the grommets to gently attach the windshield to whatever mounts you make and allow for expansion/contraction.

Thank you. I searched and Home Depot has one ready to go for $335.85, which does make buying one already done a better idea then making one myself.

Kolpin Kawasaki Mule 4/4 Full-Tilting Windshield-25 - The Home Depot

 

[westcliffe01]

The glass windshield for my Kubota was only $300. I would really try to get a glass windshield, way easier to clean and no scratches.

Where are you guys getting your plexiglass? I need a piece to make my own wind shield on my Kawasaki Mule that's 36x52 inches. I can only find 1/4 inch thick in 48x96 online, and Amazon is the best price I've found so far.

Amazon.com: 1/4" X 48" x 96" Clear MAKROLON GP (general purpose) Polycarbonate Sheet - Film Masked: Industrial & Scientific

The cost of shipping adds $147.50 to a $112.85 piece of plexiglass. That's just crazy!!!