[Mike Donofrio]

Originally Posted by dyogim

Has anyone worked with Lexan and used it to form around curves? Here's my idea. With all the rock rash I've got on my lower panels, I'm debating on either banging them out and do the whole body repair thing or just cover it with some Lexan. On another note, I'm getting some rock sliders to avoid future lower panel damage. Back to the idea. I want to use the Lexan(1/8" thick) and use a heat gun to form around the curves of the lower part of the doors. Once it's all molded, have it sprayed with Line-X and have it mounted using some small bolts. For now this is just an idea as fund$$$ is somthing I'm currently lacking. Is this possible and how hard is it mold the Lexan?

Mike, I worked with Lexan quite a bit in the 90's for lizard cages and the like. AFAIK Lexan is the most durable substance known to man...With the right heat it can be molded (although this weakens the material) Steam will generally turn it white, but a quick dip in boiling water will generally allowe it to be bent somewhat without deforming. Most times you wind up witha crease and weaker material. And at over $100 for a 4 x 8 sheet, it's not cheap to learn on. But it can be drilled, cut with a recip saw and is generally resistant to mechnical wear. There are a few companies that I know back in NJ who can aquaform Lexan to do curves and the like for fish tanks, but these are generally expensive. I used to bug them for scrap for project work and they almost always stuff that I could use. In your case a botched, curved corner, Lexan tank could use a few useful pieces. Start with TAP Plastics ( in the phone book and start hunting for Lexan dealers/fabricators. I would think Rockrails would be cheaper, but I would KILL for some Lexan body panels.