Well i made my heat shield the other day and it looks like crap. the plastic i bought dind't want to cut, just shatter. i was able to work with it enough to get it on the car, so its functional... but i need to rebuild one...

anyone have any sugestions on what material to use?

well I went to Home Depot but i bought the cheaper stuff. so its probibly low grade.

I work at a plastics R&D place, so we have a lot of tools for working with plastics. i used a band saw with a carbide grit (medium) blade and a wet saw (or tile saw) with a medium grit carbide blade. even when drilling holes in it to bolt everything together it cracked like crazy...

so the Lexan is the way to go then...

is that what you are talking about?

ya, ignor the fancy bit thing but thats the tool then, ok. gonna try and do this second one right!

i have a good dremel tool, i wonder if i can get a good bit for it that will do something similar.