Polycarbonate or Lexan windows

[mikelbeck]

Has anybody ever made their own polycarbonate or lexan windows?

[Supershafts]

Flat side windows for a boat

[82GT]

Many moons ago I helped a friend. He did the back window in a 71 Mustang Mach 1. He got a 4' x 8' sheet of the scratch resistant stuff (MIR 122 or something like that). It comes in 2 thicknesses, the thin stuff is real floppy.

Nice weight savings, plus he went with the smoked, looks almost like the factory tint.

[mikelbeck]

How easy is it to work with that stuff? There's an article in the latest Mopar Muscle about doing it yourself, they talk about cutting it to size with a jigsaw. ?

[82GT]

Yep, That's how we cut it, real easy to work with. Just have to be careful not to make too sharp of a turn.

Just a word of caution, get the scratch resistent stuff!!

[mikelbeck]

Yep, That's how we cut it, real easy to work with. Just have to be careful not to make too sharp of a turn.

Just a word of caution, get the scratch resistent stuff!!

Yeah, that's what I'll be getting. I'm thinking about replacing all the windows over the winter.

[Art]

Most poly/Lexan I've worked with came with protective paper on both sides. One side is plain, the other with the Mfg's logo and whatnot. You should be able to layout what you want shape wise by just tracing on the plain side. Jigging it will require a jigsaw with I would think at least a 24" throat.
When I helped out on a AA/FC in the early 90's, we cut a replacement windshield for the body with shears(!) at a match race one night. ( I wish I could remember how thick it was......1/8 sounds right)

[mikelbeck]

Thanks for that info, Art.

How much of a difference is there in weight from a stock windsheild to a poly or Lexan one?

[Art]

I have hunted on and off today and cannot accurately answer that. I used to have a book here with that sort of information,but since we moved it seems to have gone missing. A 3/16" thick sheet of just generic polycarbonate is $139.74 from Mcmaster-Carr. (plus freight) It is thier item number 8574K74 (www.mcmaster.com) If you could get the shipping weight you could prolly figure it that way. Also too remember that OEM windshields tend to be heavier that the current replacements that are sold today. Front shields in particular were like two shields in one with the "safety" film and all. If I had to guess, I would think in the nieghborhood of 30 to 40 lbs. lighter.

[betcha618]

i know my boy did his back window in his camaro and he laid a flat piece on the stock window and the headed it till it took the stock windows shape and then cut off the extra. it worked out nice.

[dynodon113]

I Forgot The Name Of The Place. If You Get Of Wantagh Pky At Old Country Rd. West The First Turn You Can Make It Is Right Against The Pky. Go To End There I A Factory There Go In Tell Them You Want 1/8 In. Poly Carb How Does About $75 Buck.s Sound. Bought One Last Year It Was $68 Good Stuf Either Paper Wraped Or Plastic . Plastic Comes Of Easier Put Duct Tape On The Bottom Of Your Jig Saw Not To Make Scratches