[Sanch627]

To those who have done this is it better to use a die grinder and cut a vertical cut, or an angle die grinder and cut a horizontal cut even with the extra material . Would leaving the extra from a vertical cut make a difference in the fit to the frame…

 

[rmartingt]

I would not use a die grinder of any sort. Get one of those oscillating multitool deals from Harbor freight. Loud but it does a great job.

https://www.harborfreight.com/3-amp-variable-speed-oscillating-multi-tool-59163.html

 

[wirejock]

Dremel Saw Max or other manufacturer variant.
Like a hot knife through butter.
Make sure the edge is sanded before moving the canopy.

 

[CZ79]

Dremel Saw Max or other manufacturer variant.
Like a hot knife through butter.
Make sure the edge is sanded before moving the canopy.

Forgive my ignorance, new builder, I assume the sanding the edge is to prevent cracks?

 

[Stoo]

I would not use a die grinder of any sort. Get one of those oscillating multitool deals from Harbor freight. Loud but it does a great job.

https://www.harborfreight.com/3-amp-variable-speed-oscillating-multi-tool-59163.html

I also used the Harbor Freight tool. Worked great and more controllable and not as messy as a die grinder.
Stewart Willoughby, 6

 

[Capflyer]

I would not use a die grinder of any sort. Get one of those oscillating multitool deals from Harbor freight. Loud but it does a great job.

https://www.harborfreight.com/3-amp-variable-speed-oscillating-multi-tool-59163.html

Interesting idea. I always used a die grinder with the disks Vans sent with the canopy. Oscillating multitools create a lot of vibration but if it's working I can see it would make a lot less mess. What blade did you find worked best?

 

[wirejock]

Forgive my ignorance, new builder, I assume the sanding the edge is to prevent cracks?

Yes. Shine a light on that freshly cut edge. You'll see all the stress risers waiting to crack.

 

[Freemasm]

Interesting idea. I always used a die grinder with the disks Vans sent with the canopy. Oscillating multitools create a lot of vibration but if it's working I can see it would make a lot less mess. What blade did you find worked best?

The finer the tooth count the better, obviously.

I'd be curious to see the effectiveness of the grout removal tool (blade) on the polymer (is it actually plexiglass or something else?). The relatively smooth abrasive surface would probably take a little longer but could lower some cracking risk. Probably overkill but a thought.

 

[toolmanmike]

My vote for Angle grinder with cutoff wheel. I tried the air dye grinder and it doesn't spin fast enough.

 

[Freemasm]

My vote for Angle grinder with cutoff wheel. I tried the air dye grinder and it doesn't spin fast enough.

Are you saying Electric Angle grinder?

For any application of a rotating wheel on plexiglass, I'd suggest caution as a minimum.

This would be a case where torque is not your friend. Blade pinch combined with the torque of a locked rotor can make for very expensive mistakes.

 

[toolmanmike]

Are you saying Electric Angle grinder?

For any application of a rotating wheel on plexiglass, I'd suggest caution as a minimum.

This would be a case where torque is not your friend. Blade pinch combined with the torque of a locked rotor can make for very expensive mistakes.

Yes, I hear ya there in pinching but I tried osilat tool, die grinder, the dremmel max and all were inferior to the control and cut quality of my good ol 4.5” electric grinder with cut off disk. I didn’t buy a special pastic disk, just what I had on hand for metal. It worked great and I had no issues.
my 2 cents. I worried over these cuts for weeks and afterwards wondered what the big deal was all about.