I have a small electronic detector (the enclosure is 80mm x 110mm externally, rectangular with rounded corners) which I need to fit into a narrow, single-pane, fixed window next to a rear door. If at all possible, I'd like to achieve this without having to remove the pane from the frame.
How should I best go about this?
Best Answer
Assuming not tempered, this is relatively easy, if tedious. If tempered, you'll have to replace the pane, as it will shatter as soon as you try to drill a starting hole. Would be easier out of the frame, though (or you could simply have a glass shop do for very easy, but probably more cost).
Diamonds are not needed to cut glass.
Drill a hole large enough to feed a carbide rod saw through. With care you can use one without a hacksaw frame, and you'd pretty much have to do that if not removing the glass from the frame. You can cut a lot faster if it's held in a hacksaw frame. Pull, rather than push when cutting, and be aware that a rod saw will cut in any direction, which is good for making your rounded corners, but requires attention when cutting straight lines. Used without a hacksaw frame you will also need to be careful not to bend it too much.
I have done this a few times on custom fish tank covers to make cutouts for filters.