Windscreen selection/manufacture/cost for new kit car design

[dave de roxby]

Forgive me if this topic has been discussed before but, for me, windscreen shape is one of the most fundamental elements of any new kitcar design and can make such a difference to the visual appeal of the vehicle.

Sadly, many kits get palmed-off with a 'Heath-Robinson' affair which may well do the physical job but is a bit of an eyesore, spoiling the overall presentation of the concept! However, the cost of a specially designed screen may be prohibitive - unless you know different. And now we have EU markings to deal with (bleedin regs yet again) for the IVA.

For some design concepts, it is tempting to use an existing windscreen from a production car, probably the cheapest route. But this immediately stamps a design parameter on the new car which may be very identifiable as being from the 'donor' car, simply through familiarity. Some shapes stick out like a sore thumb and look so obvious and uncomfortable in their new home. However, there are some designs which have managed to absorb or disguise the origins successfully.

For the two cars I am designing, both small 'roadsters' (not sevens), I just can't seem to find any suitable windscreen from any modern (and therefore correctly marked) production car. Size and shape are the problems and I just wont compromise on my design.

However, I have spied several attractive REAR screens or hatch-glasses which might just suit shapewise. Trouble is, I guess none of these would be laminated and therefore non-starters as front screens.

So perhaps someone could advise me, could a laminated screen be made economically by a windscreen manufacturer utilising an existing rear screen mould? And do the after-market 'replacement' screen suppliers even have rear screen moulds, or are these manufacuturer supply only? Any ideas on costs for small batches? Can existing screens be 'cut down' successfully? And finally, how hard would it be to make my own mould?

Grateful for your ideas please.

Edited by dave de roxby on Monday 28th March 11:36

[fuoriserie]

What type of production screen design were you considering? OEM manufaturers offer such a variety of screens that should suit any new kit car design but you can still have one bespoke and designed specifically for you.

What shape are you looking for ? you can have a nice Elise Mk1 screen at a very competitive price and can be disguised nicely in a sportscar shape...just check the Pagani Zonda...

http://www.heatedwindscreen.com/acatalog/modern-lo...

http://www.eliseparts.com/products/show/1/115/tint...

[dave de roxby]

fuoriserie said:

What type of production screen design were you considering? OEM manufaturers offer such a variety of screens that should suit any new kit car design but you can still have one bespoke and designed specifically for you.

What shape are you looking for ? you can have a nice Elise Mk1 screen at a very competitive price and can be disguised nicely in a sportscar shape...just check the Pagani Zonda...

http://www.heatedwindscreen.com/acatalog/modern-lo...

http://www.eliseparts.com/products/show/1/115/tint...

Thanks Italo. Yes, I've looked at the Elise screen which, for obvious dimensional reasons, is not far off the right size and shape I'm looking for. I hadn't twigged it had been used in the Zonda! I think the familiarity link there is broken by the fact that the Zonda is so much wider, so the screen shape gets absorbed into the larger overall shape - I must have a good look.

Have just been PM'd by someone in the know about the glass trade who says I could almost certainly use an existing rear screen as a template. Evidently there are some companies around who can offer this bespoke service. Opens up a lot more possibilities. Suppose I could cobble up my own template but that would limit me to single curvature.

Anyway, thanks for the info - I'm getting there!

[Arthur Jackson]

Some uses of mainstream screens are not immediately obvious.

[dave de roxby]

Arthur Jackson said:

Some uses of mainstream screens are not immediately obvious.

You're right Arthur - a good example.

Edited by dave de roxby on Monday 28th March 11:33

[Glassman]

The tooling up costs are usually very high, but if you have an old windscreen, or know what car it is from, I can put you in touch with a couple of people who can help you with this and who are a bit more reasonable in their costings.

[dave de roxby]

Glassman said:

The tooling up costs are usually very high, but if you have an old windscreen, or know what car it is from, I can put you in touch with a couple of people who can help you with this and who are a bit more reasonable in their costings.

Thanks Glassman for all your help!

[ColinM50]

Arthur Jackson said:

Some uses of mainstream screens are not immediately obvious.

Nah that can't be the same screen Arthur, the wipers are the other way round

[Frankthered]

How about

[Omerta]

Frankthered said:

How about

For me that just proves the point about production car screens not being the right shape - Having checked your profile I guess that's your Minari in the lower pic? Very nice... but personally I think it would be improved with a lower/shorter screen.

Edited by Omerta on Tuesday 29th March 21:38

[Arthur Jackson]

I have to disagree about the Minari. I drove one a good few years ago now and at 6 foot I was looking through the top of the windscreen with seats that weren't all that tall!! Too many roadsters fall foul of this.

[Omerta]

Or perhaps the problem is your backside is too far off the ground?

(Just reading it, that sounds like a personal insult - it isn't )

[Arthur Jackson]

Omerta said:

Or perhaps the problem is your backside is too far off the ground?

(Just reading it, that sounds like a personal insult - it isn't )

Arthur Jackson said:

...with seats that weren't all that tall!!

[Frankthered]

Arthur is right - I think the screen is the way it is for practical reasons - were it any lower it would be an aero screen!

Personally, I think it looks right, but I would say that, wouldn't I??

Each to their own!

[Omerta]

I was wondering if there might be clearance between seat and floorpan, height of the floorpan above the ground... however, you guys have sat in one and I haven't so if you say your bum feels like its close to the ground I'll take your word for it. Nice motor in any case

[mph]

I had a one-off windscreen made from scratch for my Jaguar special.

While building the car we first made a windscreen out of aluminium and this was sent off to Pilkington (I think) to make a buck from which the screen was subsequently made.

The cost of the buck was quite high, certainly more than £1,000 but the screens were less than £200 thereafter and the buck becomes your property.

It was a costly exercise but it made the car in my opinion.

[dave de roxby]

mph said:

I had a one-off windscreen made from scratch for my Jaguar special.

While building the car we first made a windscreen out of aluminium and this was sent off to Pilkington (I think) to make a buck from which the screen was subsequently made.

The cost of the buck was quite high, certainly more than £1,000 but the screens were less than £200 thereafter and the buck becomes your property.

It was a costly exercise but it made the car in my opinion.

Thanks mph. Sounds like you have gone through the same thought process as myself.

Thankfully, via this thread, I am now indirectly in contact with people in the glass trade who apparently can do small production runs or one-offs without the need for an expensive buck. I think it is like most things in life - it's not what you know but who you know!

I haven't actually tried this yet because my project is not quite at that stage yet. But it's nice to know that I should be able to get a screen of my own design when the time comes without extortionate cost.

[ricky sec b]

i have been thinking of getting a screen made but have been worried about the cost it will be just a one off if you could forward any of them phone numbers on it would be a massive help

[ricky sec b]

any one know were to start with this

[dave de roxby]

ricky sec b said:

any one know were to start with this

The clue is earlier in the thread! Try a PM.