DIY polycarbonate quarter windows

MrPerkles · MrPerkles's Garage

Hello I just made a set of polycarbonate 1/4 windows and have used 993 seals.
I bonded the plastic into the seal with sikaflex then fitted ,they went in fine but do i need to bond in the seal to the bodywork?.
I cant see how you can do this easily without making a mess,I am pleased with the 993 seals as they are a much better fit
Anybody know how its done on a 993 all my searches dont give a definate answer
toodle pip

sc_rufctr · 02:57 AM

That looks very clean... I like the way they look with no alloy trim.
I'm considering doing the same on my car.

I have heard conflicting storied about 993 windows. In one magazine article they claimed they were all glued in at the factory. I know the front windshield (which is prone to creaking) is definitely glued in. A local club member who has done the same thing as you didn't use any sealant or glue on the seals. He just used a bit of soapy water to get them in and that was it.

hdbmw · 10-03-2009, 03:52 AM

Like Peter said...very nice!
Sorry I can't help with the 993 installation, never done one. But I'll be watching because I know how I'll be treating rear 1/4 windows in the future.

ncseahawk · ncseahawk's Garage

I recommend asking John Walker up in Seattle. He is pretty knowledgeable about everything P car like...

MrPerkles · MrPerkles's Garage

Anybody know what goes in this gap (window frame face and door) or is my outer rubber trim to short ?

cashman · 10-03-2009, 08:34 AM

Just a heads up on Poylycarbonate. You have a bottle of Window Cleaner proping the window up. Never use standard window cleaner for PC windows unless it is specifically designed for PC. It will crack and craze your window. Soap and water is safest.

Also, you have standard PC. There are abrasion 1 side and 2 sides available. These materials would have a very thin hard coating on the outside that will provide a little better scratch resistance while cleaning. PC is soft material by nature. That is what makes is so impact resistance. It will "give".

Never use Paper Towels on a PC window. It will eventual haze your window which is why the AR-1 and AR-2 sides are a little bit better. It will keep them looking nicer longer.
Mark

island911 · 10:23 AM

Quote:

Originally Posted by cashman

Just a heads up on Poylycarbonate. You have a bottle of Window Cleaner proping the window up. Never use standard window cleaner for PC windows unless it is specifically designed for PC. It will crack and craze your window. Soap and water is safest.
...

hmmm... it seems to me that if the window cleaner is packaged in PET or PC (typical clear plastic bottles) it's, more than likely, fine for cleaning PC. ...esp an unstressed slab of PC. --what am I missing here? ..is there some common window cleaner ingredient which is problematic for PC?

island911 · 10-03-2009, 10:22 AM

Quote:

Originally Posted by MrPerkles

Anybody know what goes in this gap (window frame face and door) or is my outer rubber trim to short ?

You need new trim. -they shrink apparently. I have the same issue and just checked with the new pair. (which fit w/ no gap)

On the qtr window; what thickness PC sheet?

Jesset100 · Jesset100's Garage

Do tell about your door handles

TimT · 10-03-2009, 03:59 PM

hmmm... it seems to me that if the window cleaner is packaged in PET or PC (typical clear plastic bottles) it's, more than likely, fine for cleaning PC. ...esp an unstressed slab of PC. --what am I missing here? ..is there some common window cleaner ingredient which is problematic for PC?l

island911 · 05:13 PM

Thanks Tim.

You could have just said:

"Do not use cleaners that contain ammonia!"

signature65 · 10-03-2009, 06:15 PM

Why is Island always the antongist......I mean come on, common knowledge will tell you that windex is just water and ammonia....so its obviously the Ammonia.

Sorry Island but you always seem to play that card.

sc_rufctr · 10-03-2009, 06:18 PM

Should you use sealant for the 993 seal?

What did the factory do when assembling 993? Did they use sealant?

island911 · 07:33 PM

Quote:

Originally Posted by signature65

Why is Island always the antongist......I mean come on, common knowledge will tell you that windex is just water and ammonia....so its obviously the Ammonia.

Sorry Island but you always seem to play that card.

aahhh . .did you follow Tim's link? --it had the same flashing text. (humorous IMO) --I was being tongue in cheek, by repeating it.

btw, just because some says "don't use just any window cleaner" it doesn't really get to the specifics of why. --is it so awful for you that I seek more info?

btw2; Paradoxically, Windex says that their (ammonia) product is fine for PC.

Streak-free shine on glass and hard surfaces - Windex® Original Glass Cleaner

So, really... is, dilute ammonia_(aq) likely to noticeably chemically react with PC? esp during only a quick spray? I mean, even sunlight is 'bad' for PC.

MrPerkles · MrPerkles's Garage

Quote:

Originally Posted by island911

You need new trim. -they shrink apparently. I have the same issue and just checked with the new pair. (which fit w/ no gap)

On the qtr window; what thickness PC sheet?

the gap I am talking about is the gap down the side of the door frame and door ?
I used 4mm poly same as oe window thickness as i dont want any leaks

MrPerkles · MrPerkles's Garage

Quote:

Originally Posted by Jesset100

Do tell about your door handles

modified standards,ive done a few pairs like this

cashman · 10-04-2009, 06:11 AM

btw2; Paradoxically, Windex says that their (ammonia) product is fine for PC.

The ad does not mention PC? It mentions Lucite =Acrylic, Plexiglas, and Plastic = ?. It does not specifically mention PC.

Either way, PC is an amorphous plastic highly susceptible to chemical and oil attack. Ammonia is one of the chemicals. Also, the PC you purchase for window glazing is not "stress free", it is produced by squeezing hot melted PC between
(2) polished calandar rollers and it hardens quickly on-line. Stress free PC has to go through and annealing process and it does not for this product. You can purchase machine grade PC which has been annealed but that is usually 5/8" and thicker and you should only use water as a machining coolant.

The flat surface of the PC forms a skin while extruding and will offer some protection for the quick spray but you really have to be careful about the cleaner getting to the exposed cut edge.

You are correct, UV sunlight will eventually start to yellow the PC. I believe it comes with a 10 yr warranty against yellowing.

Long story short, if you are going through the process of hand cutting windows. I would suggest using Abrasion resistant PC. The hard coat will allow you get away with the incidental paper towel and Windex use and also also provide some minor scratch resistants.

Sorry for the long response,
Mark

davidbir · 10-04-2009, 07:53 AM

I made some for a car of mine-not a Porsche-two years ago and they still look like glass-people are amazed to learn it is acrylic. I got this stuff from a friend who supplies equipment to tanning salons but I don't know if it is special. I just use soap and water and a chammy to clean them.

island911 · 10-04-2009, 11:22 AM

Quote:

Originally Posted by cashman

btw2; Paradoxically, Windex says that their (ammonia) product is fine for PC.

The ad does not mention PC? It mentions Lucite =Acrylic, Plexiglas, and Plastic = ?. It does not specifically mention PC...

Right, but PC IS a plastic, and LCD's are often PC. --some coated, some not.

Quote:

Originally Posted by cashman

...Either way, PC is an amorphous plastic highly susceptible to chemical and oil attack. Ammonia is one of the chemicals. Also, the PC you purchase for window glazing is not "stress free", it is produced by squeezing hot melted PC between
(2) polished calandar rollers and it hardens quickly on-line. Stress free PC has to go through and annealing process and it does not for this product. You can purchase machine grade PC which has been annealed but that is usually 5/8" and thicker and you should only use water as a machining coolant. ...

Being an amorphous material does not make it highly susceptible to chemical and oil attack. --Again, just look at the clear plastic bottles which cleaners come in; which are made of non-crystalline amorphous plastic.-- It's the chemistry that maters,

Also, Being an amorphous (and non-crystalline) material, does however mean that it will "self-anneal" over time. Yes I realize PC can hold some internal stresses, but those are very small. Certainly not the type to increase chemical sensitivity.

What I'm really trying to get at is the degree of (in)compatibility; which you seem to allude to here:

Quote:

Originally Posted by cashman

...The flat surface of the PC forms a skin while extruding and will offer some protection for the quick spray but you really have to be careful about the cleaner getting to the exposed cut edge. ...

The thing is, until yesterday, I had never heard of a warning about using something like windex on PC. ...and I should note that my understanding of engineering plastics is important for me. Not only do I design many consumer and medical product with PC (lots of lenses and light pipes) but I've also taught an engineering plastics course for a few years.

Anyway, this warning, I suspect, is nothing more than an over-hyping of a slight incompatibility. ...but I would love for someone to demonstrate otherwise.

Aside, I have read that Rain-X works well to help protect PC. --seems reasonable.

MrPerkles · MrPerkles's Garage

I did it to add lightness not for shinyness,if when I clean the car it will be a mild detergent.More worried about leaks than scratches I can cover them with stickers of the track day circuits I plan to visit next year

Anyhow I bonded them in today with sikaflex will update re leaks in a few months time