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Re: Working with Lexan
I didn't see it specifically addressed anywhere in this thread (except in the Andy Baker "blue" index), but all polycarbonate is not the same. We have found a huge difference in Lexan brand versus other generic polycarbonates and the name brand is worth the price difference in terms of machinability and strength.
We love the stuff - it absorbs energy like crazy during the "rigors of competition". The self-tapping drywall screws work very well if you follow the instructions Warren gave for pilot hole and Lithium grease; using .375 thick Lexan you can mount into the edge and it makes a nice butt joint.
And the loctite issue Kirk mentioned - been there and done that too. It causes some sort of thermal reaction while curing that shatters the lexan from the inside.
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Close enough to taste it, too far to reach it
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