Protection Screen for skytrak

[Jtangm04]

No need for the router table. You want to use a jigsaw with a Bosch plexiglass blade to get a nice clean cut. Use the lowest speed setting on the jigsaw. Slower is better. You don't want the polycarbonate to melt.

How do you make the initial cut into the lexan? Did you take a drill and make a small hole first to fit the jigsaw blade?
Since i don't have a jigsaw but have an oscillating multitool was thinking of trying that method first, but worried it might vibrate too quickly and cause the lexan to melt.

[lyeung]

Yes, make a pilot hole with a sharp bit that is large enough to get the jigsaw blade in and then make your cut. Don't use anything but a jigsaw on slowest speed setting if you want to make a clean-cut without melting the polycarbonate. An oscillating tool is likely not going to do the job.

[brnixon]

How do you make the initial cut into the lexan? Did you take a drill and make a small hole first to fit the jigsaw blade?
Since i don't have a jigsaw but have an oscillating multitool was thinking of trying that method first, but worried it might vibrate too quickly and cause the lexan to melt.

I tried a multi-tool first. Terrible idea, it was a mess and melted the lexan. Get a jigsaw or use a router.

[wbond]

I used a dremel with the cutting bit and had no issues with cutting 6mm lexan. I got a little bit of melting when going to quick, but it knocks off the edge easily. Granted it's doing it freehand, so not the straighest edges.

[Jtangm04]

Anyone throw the lexan into the freezer for a few hours prior to cutting?

[lyeung]

No need to put in freezer. Just use a jig saw with Bosch "Plexiglass blade" and call it a day. You'll be amazed how easy and clean of a cut it will be

[awisnia]

I've ordered some IRT Infrared transmitting plastic sheet to see if it will work with no cut outs - it's the same color as the IR lens over the unit now....

[awisnia]

[awisnia]

This is what you see if you pop off the factory IRT plastic piece

[lyeung]

What is this picture that you posted? Is this the IRT sheet over the polycarbonate?

[Jtangm04]

Finally made my shield. I have a very ghetto setup compared to other posters. Almost embarrassed to post this.

Towards the end I got the hand of making the cutouts. I made 3 pilot holes with a small drill bit all right next to each other. I took a multitool and used the rectangular saw attachment. I went in at a 45 degree angle on the lowest oscillating free to avoid melting. Doing this allows the jigsaw to fit in perfectly .

[Jtangm04]

[Ironstrokes]

I've ordered some IRT Infrared transmitting plastic sheet to see if it will work with no cut outs - it's the same color as the IR lens over the unit now....

Nice, cant wait to hear the results and kinda curious to see a pic of it when you set it up too

[Genghis]

awisnia - any luck with the IR pass plexi?

[awisnia]

Tried it quickly and it didn't seem to work. it may work with the factory IRT lens popped off - not sure. However, i think the issue is reflection...if the lens is not pressed right up against the IR emitters and detectors (and cameras) there's too much bounce back. Like taking a flash photo through a window - if you get right up against it - you won't "see" the flash in the lens. I think I'm abandoning that direction and heading towards sheet metal with some very specific cut outs.

[FaultyClubs]

Clear or IR pass are around 90% transmission afaik so my guess would be reflection too. The standard solution for that is to isolate the emitting and detecting signal paths. Foam rings or whatever around detector. Depending on the physical layout that may or may not be possible.