After all the work on the interior I really want to get the car dryed in. Meaning, windows installed. of course, I have to make some changes to the windows.
The following project is entirely driven by the use of the NACA ducts in the rear quarter windows. In order to install said NACA duct, The windows have to be plastic. you can't really cut holes in safety glass. At least not ones large enough to suck air through.
Since I have to make 2 windows. Why not just make some extras. Like, 5 extras. That's right. New windows all around. I have done this before on track cars and it is simple and effective. And lexan is way lighter than glass. Like, 30% of total weight.
The process is relatively simple. I like to start with qualify scratch resistant Lexan. Acrylic will absolutely not do in this applcation. it splinters when it breaks. Should there every be an issue the nominally bulletproof lexan is what you want. Now, We don't want your HD style of Lexan. Spend the extra and get the scratch resistant. popular brand names for polycarbonate are Margard, markrolon, Tuffak, etc. They are all coated with an extra hard layer to prevent scratching. Well, let's use the words resist. It is plastic and still quite soft.
I start on a workbench and use a soft underlayment. In this case, My dogs donated their beds to support the Lexan sheet. Lay the lexan down, then put the glass on top. Push down on the curved glass and the polycarbonate sheet will take the shape of the window.
Extra curvy windows like the lower corners of the rear window may require you to pinch them together.
once the surfaces are touching, scribe a line tight around the perimeter.
Now that there is a line, remove the window and admire your work. Wait, that's later. Sometimes the line requires some touchup.
Now, cut to the outside of the line. I don't cut well with the jig saw so i cut wide and sand to shape. Actually, I could never color in the lines either as a kid.
The grinder is then used to sand the line away. I like the disc grinder for corners and belt sander (no pic) of the flat sides.
Now, Check your work. When curved the window and the polycarbonate sheet should match up. not bad if i say so myself.
I verified the seal fitment and laid on the car. yes, this will do nicely once I am ready to install.
Only 6 more to go.
Add lightness. That's always a good thing.
One last word of advice. leave the protective film in place while you are handling. This will help reduce unwanted scratches. Save those for detailing day.
Now, I am sure at least no one is paying attention to this post. that's fine. And that no one will ask about the board on top of Vecna. That board is the Official Falling Branch Ice Storm Protection Device (TM) I tried to give it an acroynm. However, OFBISPD just seemed to roll easily off the tongue. It stuck before I knew and became street lore in the Urban Dictionary. Ok, Maybe its more like we had a big ice storm. I had 8" branches coming out of the tree. I thought it would be easier to patch a fiberglass board than push the roof out. The octisserie just happened to be a great support. I admit my wife said I had to buy her a new SUP if this one broke. In the end, it worked and Vecna nor the board were damaged. They were only hit with smaller branches.