Cutting lenses by hand (a guide)

[Lopaka KaMars]

The valve 1.0 and mars aren't the easiest to do by hand w their bumps and/or curves. That have to be perfectly placed so lenses don't slip or rotate.

Yes it took me well over a couple hours apiece. Grinding, testing, grinding, testing. Am almost 'lucky' my first tries were pretty decent. I've already slacked some and messed up a cut for an Unknown. So far from perfect. Lol.

 

[TheStig]

What all did you use To make the cuts ?

Some use a hand held Dremel.
I use a Bench Grinder.
You will need a variety of different masking tapes. Some donor lenses are hydrophobic. Means, nothing sticks to it and you need a more adhesive tape. Some other donor lenses you need a less adhesive tape or you rip the coating right off.

 

[Lopaka KaMars]

Some use a hand held Dremel.
I use a Bench Grinder.
You will need a variety of different masking tapes. Some donor lenses are hydrophobic. Means, nothing sticks to it and you need a more adhesive tape. Some other donor lenses you need a less adhesive tape or you rip the coating right off.

The grinder. That's a good one that I didn't see if was discussed here before. The use of a stationary grinder and holding the lens. That's how I've been doing mine. I only do cuts with my Dremel.

As far as tapes go, I do need to try others myself. I've only tried a couple of brands so far. Mahalo.

 

[zhangsheng]

A few days ago @iamFLIP asked me if I had any tips when it comes to cutting lenses by hand. I was just about to cut a Radar lens shield for a Trenchcoat for @hondazcrxsi so it was the perfect opportunity to take some pics of the process and share how I go about it.

DISCLAIMER! This is how I do it, if you **** up your lenses its on you. Use common sense and don't rush.

First things first. The tools you need.

Pen - I use a fine tip Black Sharpie. It really needs to be fine tip so you know where to cut to.

Dremel - I use a Dremel 3000, any speeds I talk about pertain to that model. I have no clue if other models behave the same on the same speeds.

Sanding drums - I use 240 grit for the main work and 80 grit sometimes if i need to.

Cut off wheel - I use 409 wheels but 420 wheels work too, and they're 420 lol

Sandpaper - I use 80 grit and 2000 grit wet paper.

Tape - I use Scotch Blue painter's tape with edge lock. I've used plain masking tape too and it worked good enough. I've been told Frog Tape should be just as good but I've never personally used it.

Lenses - Old lenses to use as a pattern and new donor lenses to cut.

Time - I've done relatively a lot now so it takes me about 30 minutes to do an easy set like NSJ or XX Twenty and it takes a little longer to do X Metals because of the bevel. The bevel needed on X Metals is a pain in the ass. Either way, plan on a few hours the first few times you do it. You don't want to rush it. Remember you can always take more off but you can't put more back on.


For this cut I used a Radar shield lens.

Step one is to tape the lens. Try to stretch the tape a little and follow the curve of the lens and it will have less bubbles.
View attachment 560533

Next we need to take off the excess tape. Use the 80 grit sandpaper and hit the edge at a slight angle with a moderate amount of pressure and the tape will score and fall away from the edge.

View attachment 560534

When you're done you should have a well taped lens with exposed edges.

View attachment 560535

Next we need to cut the shield in half. Obviously this only applies to a shield lens. At this point I should have marked the lenses left and right. Being oval shaped they need to be marked so they don't get turned around or mixed up.


View attachment 560536

Now we line up the old lens and make sure its within the edges of the new lens. Most of the time you'll have plenty of room but this one was super tight. TWSS

View attachment 560537


Now use the fine point Sharpie to trace the old lens. Hold them tight so they don't slip while you're tracing. Get a good dark line and try to keep is consistent. I angle the pen tip a bit to get it closer to the edge of the lens.

View attachment 560539


Now you can see the line to cut. Notice the top is right on the edge. In some cases this will leave a flat spot in the lens but here I had to cut passed the line so there was no flat spot.


View attachment 560540
Both lenses traced. Now we need to remove the larger parts of material. Use the cut off wheel here to take out the big chunks. I use speed 7 or 8 on the Dremel. Don't get too close.

View attachment 560541

This is what we are left with after removing most of the meat. At this point we really need the lenses marked L and R.

View attachment 560542

Both lenses marked. Now we know top from bottom and left from right. The majority of meat has been removed from both.

View attachment 560543

Now we use the 240 grit drum to grind down close to the line. I use speed 6 on the Dremel here. You'll notice that the plutonite grinds away while the tape curls up. Get fairly close to the line and when the tape curls to the point that you can no longer see the line, STOP. Use the 80 grit sand paper and take off the excess passed the line like we did in the beginning.

View attachment 560544
Uncurl the tape before you sand the excess away.

View attachment 560545

Now we are much closer to the line. Keep going until you are right on the line. I use speed 6 here as well and when I get really close I use speed 4. Don't grind into it yet. You may or may not have to.


View attachment 560546

Once you get to the line you will see the edge is flat and ugly and it won't fit into the lens groove of the frame.

View attachment 560547

We need to bevel it a bit, not a lot, just a little. I use the 240 drum here still and sometimes the 80 if I feel its needed. It's hard to see but there is a slight bevel here. I use speed 4 from here on out. Use 3 if 4 is taking off too much.

View attachment 560548

This will not be your final bevel. We still have to fit the lens and probably shave it down a bit more.

do they have the same base curve？

 

[docrusty]

do they have the same base curve？

No

 

[BoostBear]

do they have the same base curve？

no. as an fyi if you cut a shield lens for typical 8.75 bc model your eye lashes might make contact with the lens.

This thread will become helpful in deciding what lens to cut for whatever model to retain non eyelash impeding fitment

🦘Oakley Donor Lens Quick Reference Guide 2024

Updated on 11th May, 2025 by @cacatman If you have any corrections or information to be added (including what DOESN'T work), please let me know! Check out Which Lenses and Which Rubber Parts are Interchangeable. If you read nothing else, please read the next 4 paragraphs (and the "Epilogue")...

www.oakleyforum.com

 

[zhangsheng]

no. as an fyi if you cut a shield lens for typical 8.75 bc model your eye lashes might make contact with the lens.

This thread will become helpful in deciding what lens to cut for whatever model to retain non eyelash impeding fitment

🦘Oakley Donor Lens Quick Reference Guide 2024

Updated on 11th May, 2025 by @cacatman If you have any corrections or information to be added (including what DOESN'T work), please let me know! Check out Which Lenses and Which Rubber Parts are Interchangeable. If you read nothing else, please read the next 4 paragraphs (and the "Epilogue")...

www.oakleyforum.com

Will a Jawbreaker one-piece lens deform if fitted into a Straight Jacket frame

 

[zhangsheng]

如果将Jawbreaker一体式镜片嵌入Straight Jacket镜框，镜片会变形吗？

不。顺便一提，如果你为典型的 8.75 BC 型号切割防护镜片，你的睫毛可能会接触到镜片。

这个帖子将有助于决定为任何型号的镜片切割什么尺寸，以保持不影响睫毛的佩戴效果。

🦘Oakley Donor Lens Quick Reference Guide 2024

Updated on 11th May, 2025 by @cacatman If you have any corrections or information to be added (including what DOESN'T work), please let me know! Check out Which Lenses and Which Rubber Parts are Interchangeable. If you read nothing else, please read the next 4 paragraphs (and the "Epilogue")...

www.oakleyforum.com

我想在我的 2007 款 Straight Jacket 上使用 Snow Torch 或 Trail Torch 镜片，但我几乎找不到任何适合它的 8.75 基弧镜片。

 

[BoostBear]

Will a Jawbreaker one-piece lens deform if fitted into a Straight Jacket frame

@Chris A Hardaway would have info on that more than I… I’d guess a turbine might be better option