I Don't carry the glass insurance on my cars, and I got sick of replacing windshields (w/s)
even though I got pretty good at doing it, so...
I made a Lexan w/s for my 85 Chevy Caprice battle tank.
I don't recommend doing this to a nice car, but If you want to make a Lexan spare w/s for
your new car, or if you want to replace a busted w/s with Lexan this is how...
Lexan (or other clear polycarbonate) retails for about $120 for a 4x8 sheet (3/16" thick)
That would be large enough for most w/s.
With the convex curvature of most w/s, the 3/16" thickness will be enough to eliminate flexing due to wind pressure.
Open the hood, pull back your wipers, cover the w/s with wide shelf paper, or "contractor paper", or something
you can trace around.
Tape it firmly in place, and trace around the w/s, including trim.
OR, remove all the trim and trace around the exact edge of the glass.
Remove the paper, cut out the pattern and tape it down to the Lexan,
on the side with the opaque protective film.
Use care handling Lexan, it is nearly bullet proof, but it scratches easily.
Heat from Drills, Saws, etc will make the clear turn milky, so take your time
when tooling it.
Trace the pattern on to the Lexan, and cut out the w/s.
I recommend using a Dremel with a THIN high speed cutting wheel.
It will take about an hour or so. TAKE YOUR TIME.
To install it, remove the old w/s.
Start by removing the r/v mirror.
Usually this is held on by a small Allen screw.
Leave the mirror mounting "bullet" on the w/s.
Assuming the old w/s is broken,
cover the inside of your car with drop cloth,
old bed sheets or something to
catch any glass that splinters away.
Unless you are into stained glass (blood-stained, that is)
wear gloves up to the elbow and safety glasses
and a full diver's wet-suit if you have one.
I usually cover the old w/s inside and out with a web of packing tape,
heat the edges and the adhesive ("tar") with a heat gun (or hair drier)
and push the old w/s outward from the drivers seat.
Never pry on the edges of a w/s. Always push from the inside, or
use a suction cup puller, some Auto Parts places will loan them free.
clean all the old tar and glass out of the w/s frame.
Remove the bullet from the old glass.
If any glass sticks to it, pulverize it with a hammer.
Lay the new w/s in place, and center it.
Then "roll" it across the w/s frame into the corners and check the fit.
Trim as needed.
Lay the new w/s flat on the ground or table.
Starting from the center,
drill holes (3/16") about 1/4 inch from the edges all the way
around all the edges.
Space the holes about 6-8" apart.
Lay the w/s into the frame, and use the center top and bottom holes
as a guide drill two 1/8" pilot hole into the w/s frame.
Attach the w/s to the frame with self-tapping screws
at the center top and bottom. SNUG, but not too tight.
(Don't crack the plastic)
Smear the inside lip of the w/s frame with clear RTV silicone.
From the center outward, side-to-side
Drill a hole at top, screw it down, then do the bottom.
Do the other side the same way.
Keep working it this way until you are at the side edges.
Screw the side edges down working from TOP-to-Bottom.
(You might have to trim the edges again.)
Seal the edges with w/s adhesive or RTV Silicone.
be generous.
Peel off the protective film.
Glue the r/v mirror bullet onto the inside of the w/s with superglue.
Install the r/v mirror.
Install w/s trim.
This worked well for me for several years, until I scrapped the car.
It passed State Inspection with the Lexan.
I am sure that the inspection judge simply failed to notice
that it was not Auto Glass.
I chased 2 years in it and the hail just bounced off,
while the rest of the car got trashed.
My only complaint, not major...
A dry, dirty wiper blade will scratch the plastic.
it can be polished out, but I thought maybe a
thin layer of clear nylon sheeting,
or plexi-glass over top of the lexan might work ?
Nascar teams use layers of the clear nylon stuff
that can be peeled off when dirty.
Five Star Racing products used to sell it.
Lexan WORKED FOR ME, individual results may vary.
-Truman
