Bongo Fury

I have managed to find a replacement window for my caravan but unfortunately its had the corner broken off whilst in transit, the breaker that i purchased it from has refunded my money and doesn't want the window back so i have hatched a plan of cleaning up and smoothing down the broken area the cutting off the the section i need off of my old window and bonding it in place, i am going to have to cut around a corner but the window thats gonna be butchered is already broken in another area, so whats the best tool to use to do the cutting ?

M 80NGO wrote:I have managed to find a replacement window for my caravan but unfortunately its had the corner broken off whilst in transit, the breaker that i purchased it from has refunded my money and doesn't want the window back so i have hatched a plan of cleaning up and smoothing down the broken area the cutting off the the section i need off of my old window and bonding it in place, i am going to have to cut around a corner but the window thats gonna be butchered is already broken in another area, so whats the best tool to use to do the cutting ?

A pull saw I reckon. Take it slow because if they jam it is very easy to put a kink in the blade. I have done almost invisible repairs in kitchen worktops using one.

Would a dremel type hand machine work, they have loads of different cutting tools and the machine has variable speeds.
http://www.amazon.co.uk/PIECE-DREMEL-DR ... 218&sr=8-1

Yeah i was thinking dremel with a side on cutting wheel or maybe a jigsaw with a very fine blade. pull saw is defo a good idea to, thanx for the input guys.

I was thinking dremel with a guide to cut against to stop it wandering, if using a pull saw it would have to be very fine and careful as suggested?.

M 80NGO wrote:Yeah i was thinking dremel with a side on cutting wheel or maybe a jigsaw with a very fine blade. pull saw is defo a good idea to, thanx for the input guys.

A jig (no matter how fine the blade) may jam & shake, splitting the bu66ery out of it...? Some sort of hand tool, in short/small increments...?!!

dobby wrote:I was thinking dremel with a guide to cut against to stop it wandering, if using a pull saw it would have to be very fine and careful as suggested?.

Had an idea for a pimp with the smoked lid off a cheap Broken under bed box... Looks like similar material to the window...?? Turned to a "no go" in the end... Now i know why the bed box cracked!!

you will need a steady hand!

Unsuitable

dobby wrote:Unsuitable

M 80NGO, I'm not suggesting yer window was cheap.....

"the breaker that i purchased it from has refunded my money and doesn't want the window back"

jaylee wrote:
Had an idea for a pimp with the smoked lid off a cheap Broken under bed box... Looks like similar material to the window...?? Turned to a "no go" in the end... Now i know why the bed box cracked!!

You did get it free! Take yer time with it &, i reckon it'll be the bargain of the century...

Hi
X-Acto knives have a large range of saw blades, but I find that the best, and easiest to use on plastic is the No. 1 Handle, and the No. 13 razor-saw blade. After cutting, glue some fine abrasive paper to a strip of wood, so that it can be used as a file to finish and square the edge. The No. 13 blade can be used as a push saw or a pull saw, but for most applications works best as a pull-saw.
Above all, take your time, and stay clear of power or rotary tools, as you will most definitely crack the window if it snags.
The other alternative is a "Hot Knife" with an electrically heated blade....if you've never used one, practice first, as they can be messy
Good luck!
Cheers
Helen

these windows are usually acrylic.
the best tip i can give you on cutting this is to slightly warm it with a heat gun or hairdyer before cutting it,dont get it too hot though or you will clog the blade.

when you have got the two halves about right and are ready to glue the two bits back together(double glazing) warm them both up and glue quickly and seal the edge,as it cools it will pull a slight vacuum, if you dont the moisture trapped in the unit will drive you mad.