Custom cutting glass/pc?

[Buck91]

Well, I'm looking to cut out a new window for my mountain bike headlamp... Only problem is that it needs to be a custom shape. Basically, a figure eight, but with three lobes instead of two (think ooo but all connected).

Has anybody done a project like this? What would be a way to go about cutting glass in this manner? Heck, where could I find optical grade polycarbonate or similar? I've never done anything like this and don't really know where to start :thinking:

 

[G1K]

You could get a sheet of clear plastic from someplace like US Plastics and use a dremel to rough out the shape. An alternative is to mill the profile. Or use glass and a glass cutter? The glass you'd be able to cut may not be the safest thing for a headlight lens.

http://www.usplastic.com/catalog/category.asp?catalog_name=USPlastic&category_name=21314&Page=1


R