I built an aerobatic airplane a few years ago and I made several panels with Lexan. It bends just like sheet metal. You do not have to heat it. You can also shape it with a roller, route it, drill it and scroll saw it. Drilling it does not take a special bit as the suppliers would like you to think, so don't buy the one they sell, just use a regular bit that you would use for steel. The thermal expansion is much higher than that of most metals, so drill your holes slightly larger to avoid cracking around the hole later. Sharp or uneven edged can be cleaned up with a file or sand paper. Good luck.
------------------ David Otero Ace Signs Albuquerque, NM
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Here's how it works. We have a heat strip in the studio that does up to 4' widths of Lexan. It takes approximately 5 times longer than acrylic. If its' a large curve, like a windshield, you block the center twice as high as the deepest point required and then block both ends with 2x4s screwed into a substrate (plywood) and jam the lex. Now position 2 double banks of halogen lights over the top and leave it. The bend will stay, but it will return the center to about 1/2 what you started with.
------------------ St.Marie Graphics & Makin' Tracks Sound Studio Kalispell, Montana stmariegraphics@centurytel.net http://www.stmariegraphics.com 800 735-8026 We're chiseling every day of the week! :^)
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