14/08/2026
We reglazed a broken corner on an Extreme 745 game king this week.
They are thin flat polycarbonate cold bent around the corner.
It was smashed by a sinker.
“But polycarbonate is bullet proof!”
Polycarb goes brittle as it ages.
We will only replace them with moulded acrylic.
Polycarb has very good impact resistance when it is new but it doesn’t like long term stress, especially the hardcoated sheet.
FYI
The minimum cold formed bend radius for uncoated polycarb is 100 x the thickness. So 300mm radius for 3mm sheet. Pretty tight.
Hardcoated is 150~ 200 x the thickness so 450 to 600 mm. Too big for most corner pieces
Polycarb is not really suitable for most windscreen corners long term. The cold forming ages it quickly and it goes brittle.
Cheap types of hardcoated polycarb are much worse. The cheap sheet has an acrylic coating rather than a silicone coating and that makes the sheet more prone to aging and crazing of the coating in our relentless sunlight.
Note, while i think of it…
If you are putting polycarb on your race car we strongly recommend against the urge to countersunk any holes.
Looks cool for a while but countersinking is a strong stress raiser.
It will crack off the screw holes in no time.
Better to use button head screws if you have to screw polycarbonate onto something….
