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Hi Tony,
That's right, I'm making new lenses out of 4mm coated polycarbonate.
Polycarbonate won't melt. It's the stuff that manufacture make headlights out of anyway.
If anybody needs 2mm polycarbonate to make a cover, I can supply a strip big enough to make about 6 covers for £10 plus postage, along with a pattern for you to cut out.
Polycarbonate sheeting can be cut using a handsaw, jigsaw, hacksaw, possibly even tin snips at low thicknesses. Rough edges can be dry sanded and clean edges can be wet sanded to improve the finish.
PM me if you're interested.
Damian
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