Master Replica Pinch Fix "How I did it!"

I'm seeing about having some T-visors laser cut. If things work out, I'll let everyone know.

I suspect there may be an even easier way to fix the pinch.
 
Where do you find a Plexi glass cutter? At a craft store, or will a sharp Xacto do the trick?

any hardware store should have them. the shields are thick. You need a heavy duty plexiglass cutter to score it. I think an xacto knife is too thin and would dull if you tried to score plexi glass with it.

acryliccutter.jpg
http://www.makezine.com/images/tools/acryliccutter.jpg
 
any hardware store should have them. the shields are thick. You need a heavy duty plexiglass cutter to score it. I think an xacto knife is too thin and would dull if you tried to score plexi glass with it.

acryliccutter.jpg

Okay, so you score it, but you don't go all the way through . . .

I'm going to look into the laser cut option, but I think it would actually be etching deeply. Will have to see. My second MR should be here on Tues.
 
wondered if some one could sort the pinch on my MR ESB lid for a small fee ???
shouldnt the visor be green for esb ?

I had an MR before and got rid of it because of the shape. It just bothered me too much. I really think my idea will work, and it's very simple, but I'm not going to say until I try it out on Tuesday. I don't want to look like a fool for oversimplifying if my idea doesn't work ;)
 
I successfully cut my replacement visor without any breaks or anything. The fit was so good, it stayed in place without securing, though of course I will lock it in to elimnate the gap, especially in the upper right corner as you're looking at it, since that is part of the shaping problem too.

My idea for a really easy fix didn't work out, though. Had to fix it by the new standards.
 
Well...thanks to Nathan, I finally got up the courage to try this. Danged if I didn't get the exact same gap on the left side. Tomorrow I plan to sit with glue in the obligatory position for thirty minutes. The welding shield is a heck of a lot thicket than the MR visor, so it really reinforces the new shape. Tutorial rocks right down to the toothpicks. I'll post a picture when the visor is glued. I used a dremel to cut the visor. Sounded easier and cuts like butter.
 
The plastic 2-part epoxy didn't work out so well for the visor left visor edge that had a gap. Today I decided to countersink small bolts into the conners that gap. I think that'll probably do the trick. Tutorial still rocks, just a slight modification to the process. Everything else is the same.

DSCN2230.JPG
 
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...And, done! Bolts worked like a charm. Still used some JB Weld for good measure like the tutorial suggest, but I think the two bolts would almost have done it all on there own.

Helmet Fix.001.jpg
 
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