Anyone made their own polycarb windows?

[Matt_N]

In a quest to get my Colt as light as can be, I'm looking at getting some polycarb windows, the only trouble is no one makes a kit for them or its newer brother the Proton Satria (or that I can find anyway).

Was just wandering if anybody on here has successfully made their own?

[mat205125]

It was a long time ago, and they were perspex, but yes.

Just take your time and keep the protective coating on until you have finished all cutting and shaping (and fitting too if possible!)

I'd advise against perpex as it scratches really easily and can break into nasty sharp dagger shapes in an accident. Make sure you get the "UV protected" polycarb.

Finally, consider sacrificing a little of the weight saving by keeping the drivers door winder mechanism if you dont go for sliders in the windows. Its soooooooooooo much easier!!!

[Matt_N]

Im going to attempt the rear windows first.

How do you go about getting them back on the car?

Did you use some sort of bondant or make them to fit the exisiting seals?

[mat205125]

You can cut them exactly to the standard size and then refit with the standard rubbers for max neatness using the string method. For ultimate lightness many bond in with silicone or self tapping screw into the aperture. You will need the window larger than the glass you remove if you do this.

For the sake of a poo and a haircuts weight, I'd go with standard rubbers to look neat and stay watertight

[Matt_N]

Cheers.

Yeh, I'd like to keep the standard rubbers if I could.

Just need to track down some polycarb sheets locally now.

[mat205125]

Final tip is some 2" wide paper masking tap on the profile where you will cut. Much clearer to mark out and extra protection from the foot of the jigsaw.

We wanna see pics too

[Alfatim]

Be interesting to know how you get on finding the polycarb and how much it costs.

Poly windows in a kit for my Alfa are £300+vat

[johno_78]

I used lexan for all the side windows on my 205 for a cost of about £85.

I bought a sheet of lexan for about £70 and cut to shape using cardboard templates i had mocked up. They are bonded to the car using tiger seal adhesive and riveted so they wouldn't fall out while the glue was drying.

[Alfatim]

johno_78 said:

I used lexan for all the side windows on my 205 for a cost of about £85.

I bought a sheet of lexan for about £70 and cut to shape using cardboard templates i had mocked up. They are bonded to the car using tiger seal adhesive and riveted so they wouldn't fall out while the glue was drying.

Where did you get the lexan?

[Matt_N]

Alfatim said:

johno_78 said:

I used lexan for all the side windows on my 205 for a cost of about £85.

I bought a sheet of lexan for about £70 and cut to shape using cardboard templates i had mocked up. They are bonded to the car using tiger seal adhesive and riveted so they wouldn't fall out while the glue was drying.

Where did you get the lexan?

Be interested to know too.

[GC8]

I would buy acrylic sheet (Perspex) rather than polycarbonate (Lexan/Makrolon etc). Im sure that some people are foaming at the mouth reading this and will be keen to share their wisdom about how it will shatter etc; but in reality whilst its not quite as impact resistant as polycarbonate, its massively stronger than glass. The real advantage with acrylic is that it is far more durable. It will resist scratching far better than even the expensive Margard coated types of polycarbonate; and you can polish it back up too, as well as resisting weathering.

RED Ltd (plasticonline.co.uk) are reasonably priced and well regarded. If youre using PC then you should use 4mm sheet, although you can get away with 3mm. If using acrylic then Id stick to 4mm. Polycarbonate is dearer, but if you really look about you should be able to source 4mm sheet for £25 per square metre. RED are dearer, but theyre far cheaper than most other vendors advertising.

Other advantages of acrylic are that it transmits more light and gives better optical clarity than polycarbonate and it doesnt yellow over time - also, as mentioned: you can polish it up, which you cant do with polycarbonate. With regards to strength: polycarbonate is approximately 30x as resistant to shattering as glass, whereas acrylic is around 20x as resistant. Hardly the hazard that some people like to suggest and massively superior to glass...

Edited by GC8 on Sunday 11th April 03:53

[GC8]

mat205125 said:

I'd advise against perpex as it scratches really easily and can break into nasty sharp dagger shapes in an accident. Make sure you get the "UV protected" polycarb.

Perspex is actually far more resistant to marring than polycarbonate. Unfortunately all polycarbonate will be affected by ultra violet light quite quickly.

[johno_78]

Matt_N said:

Alfatim said:

johno_78 said:

I used lexan for all the side windows on my 205 for a cost of about £85.

I bought a sheet of lexan for about £70 and cut to shape using cardboard templates i had mocked up. They are bonded to the car using tiger seal adhesive and riveted so they wouldn't fall out while the glue was drying.

Where did you get the lexan?

Be interested to know too.

I used to deliver to these guys http://www.angliarubberandplastics.com/ so picked a sheet up one day. I'm sure there are plenty of other such places dotted around in various industrial estates.

[mat205125]

GC8 said:

mat205125 said:

I'd advise against perpex as it scratches really easily and can break into nasty sharp dagger shapes in an accident. Make sure you get the "UV protected" polycarb.

Perspex is actually far more resistant to marring than polycarbonate. Unfortunately all polycarbonate will be affected by ultra violet light quite quickly.

.... but wont leave you looking like a stunt double from the snooker hall scene in the Krays if it all goes "bleed nipples up"

[TheLurker]

How much weight can be saved by replacing the windows, say, per m^2?

[GC8]

The specific gravity of glass is about 2.60 whereas acrylic/polycarbonate is about 1.18/1.20.

[Alfatim]

Wicks, Acrylic sheet 1800x900 £21.99. Not sure what thickness though, will try and find out




2mm

Edited by Alfatim on Wednesday 14th April 08:01

[GC8]

Dont go below 4mm with acrylic. Polycarbonate shatters into shards too though, just like acrylic: try bending a CD too far...

[Lefty Two Drams]

TheLurker said:

How much weight can be saved by replacing the windows, say, per m^2?

Not that much surely?

[mat205125]

Lefty Two Drams said:

TheLurker said:

How much weight can be saved by replacing the windows, say, per m^2?

Not that much surely?

A worthwhile amount, definitely!