Since the headliner was in, it was time to complete some of the windows.
I had already described the rear deck mounted ICs for the turbo setup. It was time to make this a reality. I had purchased some NACA ducts with a flat flange around the perimeter. This was to bond the lexan duct to the polycarbonate window panel. FWIW, Lexan is a brand name of a polymer polycarbonate. They are the same thing and I use the terms interchangeably.
Now, there are some special adhesives for gluing PC material. I ordered a small bottle that came with a syringe needle applicator. The process is normally straightforward. Place 2 pcs of PC together, add some drops of adhesive and let it wick into the joint using some capillary action. The adhesive will then chemically melt the PC faces on each part together.
But... I used a scratch resistant coating. It is also apparently adhesive resistant and the NACA duct did not stick at first. So, I had to scuff the coating to get it to stick. This caused some visual opaque-ness to the joint. Oh well.
Once the duct was glued I was able to cut the middle of the duct for access. I then smoothed the edge with a dremel tool. When the duct modified window panel was complete, I put on the seal and the trim.
Of course, Now I had these windows and the safest place for them was on the car. First up was the rear window. What fun that is solo. A new seal is soft but stiff. The trim doesn't want to stay in place and to really make things worse, the "glass" PC sheet is quite a bit larger when you unroll a curved shape flat. The advantage was that I didn't have to worry about breaking it when it was manhandled into place. Eventually the rear was roped in.
And then, the sides were installed. these two went in quite easily.
Oh, did I mention that the look of the NACA duct in the window is 1005 Bad-Ass! I can't wait to see this in action.
I will also say that pulling and pushing and gripping rubber seals, trim, glass and pull strings takes a toll on our hands. After all this, my hands looked like a war had gone through. They were blistered and all my callouses were coming off.
At least its just a flesh wound. Consistent with the Black Knight I will continue my fight to make this car a reality.