|
|
|
|
| Author |
|
|
Administrator
Join Date: Feb 2000
Location: Los Angeles
Posts: 13,333
|
Replacing rear quarter windows: What's the best way to cut Lexan?
Also, if anyone has any pointers on replacing the glass/Lexan in early pop-out quarter windows, I'm all ears. Is there a way to minimize the stress of dealing with those seals?
I've been told a jigsaw with a fine-tooth blade is best. But I've also been told to use a multi-tool. I have some hazy vent and quarter windows -- and enough material on hand to do this correctly just once.  
__________________
Jack Olsen 1972 911 My new video about my garage. • A video from German TV about my 911 |
||
05-21-2019, 10:48 AM
|
|
|
Registered
Join Date: Jan 2018
Posts: 675
|
Waterjet...
|
||
|
05-21-2019, 10:52 AM
|
|
|
Under the radar
Join Date: May 2007
Location: Fortuna, CA. On the Lost Coast near the Emerald Triangle
Posts: 7,129
|
I'd use a bandsaw. Leave the protective plastic on till done. Then touch up with a disk sander or file. A portable jig saw would work as well.
As long as you file the cut edges to eliminate the rough or sharp edges AND the thickness of the lexan matches the glass it should be no problem installing it.
__________________
Gordon ___________________________________ '71 911 Coupe 3,0L outlawed #56 PCA Redwood Region, GGR, NASA, Speed SF Trackrash's Garage :: My Garage Last edited by Trackrash; 05-21-2019 at 10:55 AM.. |
||
|
05-21-2019, 10:52 AM
|
|
|
porsher
|
Lexan scratches just by looking through it, I would go with acrylic, esp for a side window.
Mcmaster sells jig saw blades intended for plastics, they clear the chips without melting the cut edge. Worth every penny.
__________________
86 911 Race Car, with a few 993 bits in the boiler room 79 928 Race Car 88 928 Becoming a Race Car |
||
|
05-21-2019, 11:20 AM
|
|
|
porsher
|
Did I just give advice to Jack Olsen
  
__________________
86 911 Race Car, with a few 993 bits in the boiler room 79 928 Race Car 88 928 Becoming a Race Car |
||
|
05-21-2019, 11:21 AM
|
|
|
Registered
Join Date: Jan 2005
Location: SC
Posts: 212
|
I used Macrolon.....cut with bandsaw. Had no real issues installing in rear quarter pop-outs.
|
||
|
05-21-2019, 11:43 AM
|
|
|
|
Registered
Join Date: Oct 2004
Location: San Diego
Posts: 4,870
|
I've just used a jigsaw with a fine blade in the past. Bandsaw would be nice option too if you've got one.
|
||
|
05-21-2019, 12:00 PM
|
|
|
Administrator
Join Date: Feb 2000
Location: Los Angeles
Posts: 13,333
|
Quote:
I used Macrolon.....cut with bandsaw. Had no real issues installing in rear quarter pop-outs. I've never done these before. Is it possible to pop the piece in, if I reuse the old seal, or do I need to disassemble some of the frame so it can slide in?
__________________
Jack Olsen 1972 911 My new video about my garage. • A video from German TV about my 911 |
||
|
05-21-2019, 12:04 PM
|
|
|
Registered
Join Date: Sep 2007
Location: Wheaton, IL (Chicago 'burbs)
Posts: 3,141
|
Jack, I used the same Polycarbonate sheets from McMaster. I’m fortunate that their HQ and primary distribution center are just 30 minutes from home.
I cut it with Bosch 21 teeth per inch bi-metal blades in my Milwaukee cordless jigsaw. Worked flawlessly. I also used 2 layers of blue painters tape along the cut line for extra scratch protection even with the protective film still on both sides. I just cut very slowly, had to blow off the cuttings from the surface, the blade does a such a good job of self cleaning that it would obscure my cut line mark every few inches. Can't offer thoughts on installation, mine are installed in 993 seals, not pop outs. 
__________________
Ed '86 911 Coupe (endless 3.6 transplant finally done!) '14 Jeep Grand Cherokee 3.0 Turbodiesel (yes they make one) '97 BMW 528i (the sensible car, bought new) '12 Vintage/Millenium 23' v-nose enclosed trailer Last edited by 175K911; 05-21-2019 at 01:47 PM.. |
||
|
05-21-2019, 01:41 PM
|
|
|
Under the radar
Join Date: May 2007
Location: Fortuna, CA. On the Lost Coast near the Emerald Triangle
Posts: 7,129
|
You have to disassemble the frame. It's been a while since I did mine, but IIRC there are small screws that hold the front straight piece on. I had no problem re-using my seal, but that was years ago.
Probably too late for you, but I used tinted plexi on my car.
__________________
Gordon ___________________________________ '71 911 Coupe 3,0L outlawed #56 PCA Redwood Region, GGR, NASA, Speed SF Trackrash's Garage :: My Garage |
||
|
05-21-2019, 03:40 PM
|
|
|
Registered
|
I highly recommend the Bayer Makrolon sheet material.
Best way to cut this (other than waterjet) is to use your previous window as a template (or use it to make a soft MDF template), double-stick-tape the template to the sheet, and then use a router table and bearing bit to trace/cut the new window from the template. |
||
|
05-21-2019, 05:51 PM
|
|
|
Registered
Join Date: Jan 2003
Location: Langley,B.C.
Posts: 12,000
|
Always have used a jigsaw with a fine tooth blade and always worked well. If I had a bandsaw I would have used that.
Cheers
__________________
Turn3 Autosport- Full Service and Race Prep www.turn3autosport.com 997 S 4.0, Cayman S 3.8, Cayenne Turbo, Macan Turbo, 69 911, Mini R53 JCW , RADICAL SR3 |
||
|
05-21-2019, 06:19 PM
|
|
|
|
Registered
Join Date: Jan 2008
Location: Gastonia, NC
Posts: 666
|
Scratch resistant can be either 1 side or 2 side. Not sure what what they sell but the masking should be labelled. Also the scratch resistance is just a very thin coating. Still need to be careful with it.
__________________
1989 911 Carrera Cab 25th Anniversary Edition Euro Pre-Muffler, SW Chip There's nothing better than: Listening to "Going Down the Road Feeling Bad" ,as I, "Go Down the Road Feeling Bad" |
||
|
05-21-2019, 07:51 PM
|
|
|
Registered
Join Date: Jan 2003
Location: Langley,B.C.
Posts: 12,000
|
The best stuff we have used over the years when cutting our own windows is Lexan MR10 Margard. Scratch resistant on both sides and quite durable.
Cheers
__________________
Turn3 Autosport- Full Service and Race Prep www.turn3autosport.com 997 S 4.0, Cayman S 3.8, Cayenne Turbo, Macan Turbo, 69 911, Mini R53 JCW , RADICAL SR3 |
||
|
05-21-2019, 08:05 PM
|
|
|
Registered
Join Date: Jul 2005
Location: Seattle
Posts: 5,823
|
hmm.. haven't tried to cut Lexan on my laser yet....
[edit] nevermind. Lexan laser cuts like crap.
__________________
'85 911. White - 53,000 miles bought 3-16-07. "Casper" '88 924S. Blue - 120k miles bought with 105k miles. '94 968 Coupe - White - 108,000 miles bought 9-28-17 '09 Cayman - Grey - bought 9-8-20 Last edited by WolfeMacleod; 05-21-2019 at 09:18 PM.. |
||
|
05-21-2019, 09:15 PM
|
|
|
Registered
Join Date: Jan 2005
Location: SC
Posts: 212
|
Quote:
|
||
|
05-22-2019, 01:58 AM
|
|
|
Get off my lawn!
|
I would bet if you called a few plastic specialty shops you will find one with a computer controlled router. We have a local company that can just scan the old part, clean it up a bit, and cut that shape from any sort of plastic sheet you want. They would leave the paper backing on the plastic so all you have to do is peel back the edges past the rubber seal, install the window, and then finish the peel.
We used to have custom cut pieces cut by them all the time for big display booths at conventions.
__________________
Glen 49 Year member of the Porsche Club of America 1985 911 Carrera; 2017 Macan 1986 El Camino with Fuel Injected 350 Crate Engine My Motto: I will never be too old to have a happy childhood! |
||
|
05-22-2019, 05:38 AM
|
|
|
I would rather be driving
Join Date: Apr 2000
Location: Austin, TX
Posts: 9,108
|
Did this years ago and used Margaurd Polycarbonate. I made rear quarter panel, side roll-up and front wing quarter windows. They lasted for about 10 years before needing replacement. Careful cleaning when dirty. Make sure they are very wet before wiping dirt off. I had more issues with UV crazing over time than direct scratches.
Tape the edge profile. Lay on a pillow or soft surface. place old window on top. Its curved so you want to account for the curve by allowing PC to recess into the window shape. Trace profile. Use fine blade to cut to outside of profile line. Use belt sander to trim into line. Assembly, remove old seal from Quarter window frame. \ There are 2 screws top and bottom. Remove the screws and slide out vertical frame section from rear curved frame section. Slide out glass and glass seal. Install seal on PC "windows" slide into frame reinstall front vertical section and secure screws install exterior seal. Cuss and swear and complain when it doesn't fit into channel Eventually get seal installed. Put back in the car.
__________________
Jamie - I can explain it to you. But I can not understand it for you. 71 911T SWT - Sun and Fun Mobile 72 911T project car. "Minne" - A tangy version of tangerine #projectminne classicautowerks.com - EFI conversion parts and suspension setups. IG Classicautowerks |
||
|
05-22-2019, 06:24 AM
|
|
|
Registered
Join Date: May 2019
Posts: 167
|
I used to cut polycarbonate on a router table with a pattern bit and a template of 1/2 inch plywood taped to the plastic. You just have to make sure you keep the workpiece moving or it could melt. Makes a nice clean factory-looking edge with no trim or sanding required, unless you melt it
|
||
|
05-22-2019, 07:28 AM
|
|
|
Registered
Join Date: Jul 2000
Location: So. Calif.
Posts: 19,910
|
You can do it by hand unless you're in the biz. Use the recommended jig saw blade and cut close to the line. Then use a belt sander, drum sanders and files to trim/finish to size/contour. The edges don't show so they don't have to be polished. And of course, protect both sides until it's installed. Take extra care when cleaning to reduce scratches.
Sherwood |
||
|
05-24-2019, 03:17 PM
|
|
My Garage
1971 Porsche 911
Baja Bug
Carrera
