DIY Polycarbonate /Makrolon enclosures

[ttmott]

Probably a question for @KevinC....
I've been making (sewing) my own canvas enclosures for some time now using pressed and polished vinyl's. I've actually got it down pretty good.
I want to make the front glass on the bridge of my boat using Makrolon but it seems I can't purchase it for DIY purposes. It's apparent the Manuf. only wants qualified fabricators to have access to the material...
I understand the Polycarbonate products are glued to the canvas and caution needs to be exercised when cutting the material but why can't someone like me purchase the material??
Thanks
Tom

 

[ranger58sb]

EZ2CY (and successor?) is glued. Our Makrolon has always been sewed.

-Chris

 

[PlayDate]

Probably a question for @KevinC....
I've been making (sewing) my own canvas enclosures for some time now using pressed and polished vinyl's. I've actually got it down pretty good.
I want to make the front glass on the bridge of my boat using Madrolon but it seems I can't purchase it for DIY purposes. It's apparent the Manuf. only wants qualified fabricators to have access to the material...
I understand the Polycarbonate products are glued to the canvas and caution needs to be exercised when cutting the material but why can't someone like me purchase the material??
Thanks
Tom

Looks like they have their hands full with corporate customers which is what they are focused on. Handling consumers directly is a lot of overhead and much smaller sales. It is however a business opportunity. That's how I got into the laminate business.

You just have to buy enough from them annually for resale to make it worth their while.

 

[ttmott]

EZ2CY (and successor?) is glued. Our Makrolon has always been sewed.

-Chris

Interesting. I don't think my machine can punch through the Makrolon. Throw EZ2CY in the mix also...

 

[ttmott]

Looks like they have their hands full with corporate customers which is what they are focused on. Handling consumers directly is a lot of overhead and much smaller sales. It is however a business opportunity. That's how I got into the laminate business.

You just have to buy enough from them annually for resale to make it worth their while.

Possibly but even the canvas shops will not sell it. Suprisingly, Sailrite does not stock it.

 

[PlayDate]

Possibly but even the canvas shops will not sell it. Suprisingly, Sailrite does not stock it.

I agree.....but there is always a story and it usually is rooted in economics. If Sailrite (who I really like) can't get the margin they want......then why carry it?

They already have Strataglass, O'Sea, Plastipane and Regalite.

 

[KevinC]

Probably a question for @KevinC....
I've been making (sewing) my own canvas enclosures for some time now using pressed and polished vinyl's. I've actually got it down pretty good.
I want to make the front glass on the bridge of my boat using Makrolon but it seems I can't purchase it for DIY purposes. It's apparent the Manuf. only wants qualified fabricators to have access to the material...
I understand the Polycarbonate products are glued to the canvas and caution needs to be exercised when cutting the material but why can't someone like me purchase the material??
Thanks
Tom

Tom,

Makrolon as a brand was sold to Plaskolite and now sold as TUFFAK. The polycarb material is a generic for Lexan and it is sewn and not glued. I believe you would glue the acrylic sheets.

As far as supply goes I do not think it is marketed to consumers so that may be part of the problem. My distributor local distributor carries 60g sheets and said they dropped the 40g when sales dropped after Covid where is was being order for PPE fabrication. There are also two grades - the standard UV and UV with scratch protection. Pricing for the SR is roughly double.

While the material is rigid it will take a bend - it will not roll like eisenglass. It can be "rolled" for shipping purposes though as it comes in 4 x 8 sheets.

It is sewn in with a #22 tripoint needle. You need a "cutting" needle to better pierce the poly. Standard needles are designed to "push" between the weave of the canvas. I use a PTFE thread and sew at a very slow speed at a long stitch length. When adding the facing I also use basting tape under the seam line - this will work to help seal the holes as well as hold the material in place. When adding the binding and zippers you will also need some binding attachments and zipper feet.

As far as you machine goes I am using a Seiko (similar to Consew) with a servo motor - have not tried it on my Sailrite. It is pretty thick material - I would think the Ultrafeed might work especially if you assist the wheel by hand. I should note that it is sewn best when laying flat - so I would recommend a recessed sewing table for this. If you are interested in try I could probably mail you a small scrap sample to test with.

-Kevin