Today was a really exciting day because I actually started cutting the plexiglass canopy. Overall, I found cutting the plexiglass to be pretty easy. It’s definitely easier than using a cutoff tool to trim aluminum. I started out the day by getting the canopy off the ground and onto sawhorses. This will make the cutting easier.
The first thing you are supposed to do is trim away the excess material around the perimeter of the canopy. There are ridges in the material where the canopy was clamped during the forming process. The directions are pretty vague, but it seems like this is the region that needs to go. I taped off the regions that need to be trimmed. The canopy is going to go through a lot of masking tape.
This picture shows the plexiglass being trimmed away from the sides of the canopy.
Here are all the trimmed remnants.
I spent a good amount of time sanding down the edges of the canopy after the cutting was done. The key is to avoid any stress risers that could result in a fractured part.
