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Posts: 2,240
Reply with quote  #1 
I had to cut a sheet in half, and hummed and ha'd for a long time, as it is very FRAGILE stuff...

After a web search, I discovered that some folks use a circular saw, others a jig saw, working horizontally on a table...  Wearing goggles, of course...

I don't possess a circular saw, and the idea of using a jig saw put me right off...

Also, the sheet with of 90 cms (3 foot) means you need kind-of LONG ARMS (which I don't have neither...)

I ended up using a simple hacksaw blade, with tape wrapped around it to form a handle.

After marking the sheet with a felt pen, I "trapped it" between two wooden battens, 1" x 2", and secured these tightly together with tape.

This makes a "jig" that makes for easier handling of the (very wobbly...) sheet.

I leant this assembly up against a bench, so I was working diagonally on the sheet.

I then cut across the tops of each ridge in turn, making a cut about 0.5" long.
Then turned the sheet over, and did the same on the "troughs" (which were by this time the new ridges).

Then it was easy to just join up the cuts.

The difficult bit, believe it or not, is cutting *ALONG* the waves...

Another web search said that a lot of folks use a utility knife, particularly if the sheet is THIN (mine was...).

I laid a line of electrical insulation tape on the sheet, and put a batten underneath,
then drew my cutting line with a ballpoint pen, and cut it free-hand with the knife.
It is risky - I got a brittle break, which fortunately was on the "right" side of the line...

SO BEWARE of the utility knife method !

I tested another -- much easier -- method :  fill a tall jug with BOILING water, then stand a heavy-bladed (non-serrated) knife in the jug for half-a minute, then CUT down the PVC with the hot blade - it will give you a few inches, before it needs warming again...  (Heavy blade holds heat better than a light blade...).


SOME OTHER PVC TIPS while we are at it...[rolleyes]

  • You can pour boiling water on the wiggly end of the sheet, then press it down to the floor, with a wooden board - this will give you a perfect transition into a FLAT EDGE (for easier fixing etc...).
  • Also works for the convex/concave edge of the sheet...
After remodeling, hold the sheet firm for a couple of minutes, till it cools, and so retains its new shape.


(1)  "Heat goes from hot to cold, there is no directional bias"
(2) It's wrote, "voilĂ " unless talking musical instruments...


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Posts: 3,053
Reply with quote  #2 
Thanks!! I never would have thought of it on my own but if the hot knife works, you can get "hot knife" tips to fit a soldering gun if you have one.

Solar is like the wind. It may be free, but putting it to work isn't!
Willie, Tampa Bay

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Posts: 2,240
Reply with quote  #3 
Thanks !

I'll give that a try

(years ago, in a flurry of modernity, I *did* happen to purchase  a soldering iron...).

(this will be the 1st time it'll've bean used...) [redface]
(if no further news, I electrocuted myself...) [confused]


(1)  "Heat goes from hot to cold, there is no directional bias"
(2) It's wrote, "voilĂ " unless talking musical instruments...

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Posts: 78
Reply with quote  #4 
The hot water trick for transitions is freaking GENIUS! I had been using a heat gun and it was temperamental at best. Thanks!
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