Anyone Work With Lexan?

[j200pruf]

Hey all, since one of my headlights on my FZR-R7 is messed up and I will need to replace them. The lights currently stick out of the bodywork which I really don't like. I was thinking of cutting the lights that are glassed into the fairing (what the hell was someone thinking) and making it look more like a stock R7. I alslo found this endurance bike and I like the headlight setup (but I would go with two lights instead of 1)



I could run them with no cover for a while but I would like to make a clear cover either way I go. But I have no idea how to form lexan or a similar material to the complex shape like I would need. Has anyone here ever messed with this stuff?

[ragedigital]

The only thing I know is that it can be milled with woodworking tools, but as far as bending, I'm not exactly sure.

I would imagine that it is like small pieces of plexi that can be heated in boiling water (double boiler) and bent in a fixture.

darrin

[thatkid]

Yeah it's basically a plexi. I used an oven to heat it and then shape it. Only problem is if you bend too much it will form a noticeable crease even though it will still be smooth. That may tweak the light being thrown through it.

[billy_awesome]

lexan is kind of a bitch, it's expensive and very touchy with heating and modding, it might not be as bulletproof as lexan, but plexi might be a cheaper solution. To bend it you need a propane tank with a flame thrower, or a big enough propane torch that can head a wide spectrum. take your sweet ass time heating it up, you might go threw a few pieces with melting them and turning them brown before you find the technique. What I do is grab a old basketball or something and sit the plastic on the ball, heat it up so the plastic melts and forms to the shape of the ball, hope this helps.

[j200pruf]

Okay so ill mess with plexi. So just heat and shape? I have some good ideas running through my head, thanks all.

Any thoughts on acrylic or poly carbinate (sp) like they make water bottles out of?

[haro504]

i would say boiling would bee your best bet, un like a flame i dont think you will burn the surface as easy.

[ragedigital]

Okay so ill mess with plexi. So just heat and shape? I have some good ideas running through my head, thanks all.

Any thoughts on acrylic or poly carbinate (sp) like they make water bottles out of?

Acrylic is what most people refer to as "plexiglass". Cast Acrylic is clearer than extruded. We used cast acrylic in the saltwater reef hobby for skimmers and such.

Not sure how to work with polycarbonate or even where to get it in sheets.