Where can I get raw lexan?
 

I have a pair of spare rear quarter windows for a 911 and I am thinking of making a mold (using some ultracal30 mold making cement I have in my basement) to fashion lexan replacements. I figure I'll apply some Amourguard (sp?) adhesive clear plastic sheet to the outsides to prevent scratching. I have a good heat gun and can also try using my oven if I need something bigger for the melting/forming process.

Anyway, while this might be a fun winter project, I am wondering where I should go to buy high quality lexan at a good price. So where do yo crazy DIY folks go when fabbing windows and such?

Also, I am wondering what thickness stock I should buy. My windows appear to be either 5/32" or 4 mil depending on whether you are metric or standard. Is this the correct thickness or should I go thinner for lexan? I am hoping to use my OEM rubber seals so I am hesistant to vary from the stock thickness. Any advice?

There is a company local to me called American Plastics. They sell Lexan in various thicknesses, and they will cut the sheets to size. I don't know is this is what you are looking for.

I'd try the Yellow Pages, look under "Plastics" and someone will be able to steer you correctly...

Any sign shop/display company will sell you some lexan.

Most glass companies can order it for you. You'll probably want to shop around; I've found some that want to mark it up quite a bit.

Have you tried an on-line search too? It could be good for price comparison.

Hey Janus,
I have a friend that owns a sign shop. When I get home from Germany I'll give you a call.
Todd

Janus, Take care when using the heat gun. Polycarbonate has a very narrow working temp. Any local plastic fabricator that stocks plastic will have what you are looking for.If no one is local try McMaster-Carr online.

Look in the phone book, you will probably find a few plastic suppliers. Keep in mind, plexiglass (acrylic) is cheaper and is more scratch resistant than lexan (which will show scatching after a couple of washes).

Plexiglass will break though while Lexan typically will not. I have made aircraft windows out of both. FWIW, most general aviation windshields are formed from plexiglas. Plexiglas can be purchased from home depot type stores.

Isn't plexiglas brittle? I always thought Lexan was darn near breakproof!

you guys are looking for lexan or ge;'s equivalent, you also want the mar resistant stuff thats the same thickness as a window, plexi glass sucks, Kevin

Janus, I made my windows with sheet from Home Depot.

http://forums.pelicanparts.com/uploa...1131921962.jpg

http://forums.pelicanparts.com/uploa...1131921972.jpg

Plexi-glas is a little more malleable than lexan and can be polished to remove imperfections/scratches. Race car glass should always be lexan as it has a much higher tolerance to strikes. Police cruisers use lexan for the front to rear seat dividers because depending on the thickness, it can be bullet proof.

Okay Jorian, wanna make some windows this winter with me....? Don't sell the shop yet!

Cheers

a few Mass. area polycarb & plexi distributors:

Sheffield Plastics - 800.254.1707
Modern Plastics - 800.243.9696
J. Freeman Inc. - 800.841.9442
Patriot Plastics - 800.229.0035

SmileWavy

Jeff,

Not sure I like how much faster your car is getting to be...

Janus,
Home Depot right by Greendale sells it, there is also Plastics Unlimited on Millbrook st. (and they sell everything imaginable). GE may still have a sales office in Holden but I haven't been there in 5+ years.

Yes, Plexiglass will break, Lexan typically does not.

So what? For rear side glass, I would go with plexi as it is cheaper and more scratch resistant. If it breaks in a roll over, who cares?

As I stated before most general aviation windshields (Cessna 172, Piper Cherokee ETC ETC) are plexiglass even though a bird strike can and does happen occasionally at 120 mph. I guess if I had a choice, I would rather have Lexan in front of me if I had a rock or something being thrown up from the car in front of me. What is behind me though, does not matter.;) :D

If you heat Lexan to mold it, be careful not to overheat it. If overheated, it will form small bubbles inside the plastic that will weaken it, so it it better to take your time and heat slowly (esp. with a heat gun) and not try to shape it in a hurry.

Plexiglass also breaks into sharp edges like glass shards.

Hey Janus,

Let me know what happens. I might be game to do the same thing. Just curious what the end expense is. I am thinking the Lexan is inexpensive but the new seals will add up.

Thanks,

David

Wow, Shaun, that is impressive. I'll take JasonAndreas' advice and get some at Home Depot. Shaun, did you form the lexan windows using heat or did you bend it some other way? And what thickness did you use? In order to keep the original seals, I am thinking of staying with the stock thickness which may limit the weight savings (but not the sheer COOLNESS factor :D). Oh yeah, one more question: What did you use to cut it?

And Dave, don't worry, if I pull this off you'll definitely see the results...;)