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Merkur rear hatch glass

Posted by Rallymech 
Rallymech
Robert Gobright
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Location: White Center Seattle
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91 VW GTI 8V


Merkur rear hatch glass
January 21, 2015 09:21AM
Has anyone replaced the rear hatch glass with Lexan on a Merkur? The glass has a lot of curvature in both planes. I wonder if a flat sheet will fit and if I can use the gasket. This isn't a big deal but I would like to loose that weight if it doesn't turn into a big science project.

Thanks.



Robert.

"You are way too normal to be on Rally Anarchy." Eddie Fiorelli.
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NoCoast
Grant Hughes
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Location: Denver, CO
Join Date: 01/11/2006
Age: Settling Down
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Merkur



Re: Merkur rear hatch glass
January 21, 2015 09:32AM
I did. I didn't attempt to reuse a gasket though. It's a little flimsy but not too bad.

That's about the only picture you can see it though...
http://nocoastmotorsports.net/Build/Merkur/Action/grantside.jpg



Grant Hughes
http://rally.build
Denver, CO
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john vanlandingham
John Vanlandingham
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Re: Merkur rear hatch glass
January 21, 2015 11:36AM
Quote
Rallymech
Has anyone replaced the rear hatch glass with Lexan on a Merkur? The glass has a lot of curvature in both planes. I wonder if a flat sheet will fit and if I can use the gasket. This isn't a big deal but I would like to loose that weight if it doesn't turn into a big science project.

Thanks.

Skye and I chopped a sheet of 4x8 Lexan into 2 hatch glass pieces.. pop-riveted in, worked fine.

Stand BACK when popping the trunk release.



John Vanlandingham
Sleezattle, WA, USA

Vive le Prole-le-ralliat

www.rallyrace.net/jvab
CALL +1 206 431-9696
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is 3 hours behind Eastern Standard Time.
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johnhuebbe
John Huebbe
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Re: Merkur rear hatch glass
January 21, 2015 01:40PM
You can heat up the lexan and place it over the glass (when it's out of the car). Use the glass as a template and form. When the lexan cools, it will be in the shape of the glass. My brother and I did this with the rear glass in our VW. Worked great.
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NoCoast
Grant Hughes
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Location: Denver, CO
Join Date: 01/11/2006
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Merkur



Re: Merkur rear hatch glass
January 21, 2015 01:46PM
Thermoforming. I used to know the temperature lexan gets soft but don't recall that anymore.

I actually considered buying a pizza oven to use to manufacture lexan windows. Can also build an insulated tent and use a regular convection oven.



Grant Hughes
http://rally.build
Denver, CO



Edited 1 time(s). Last edit at 01/21/2015 01:47PM by NoCoast.
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Rallymech
Robert Gobright
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Location: White Center Seattle
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91 VW GTI 8V


Re: Merkur rear hatch glass
January 21, 2015 09:10PM
I had considered trying to form it. I'm not sure I can generate enough heat.

I want the thing to look decent and not leak.

Definitely will only use one strut!



Robert.

"You are way too normal to be on Rally Anarchy." Eddie Fiorelli.
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MattP
Matt Pullen
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Re: Merkur rear hatch glass
January 22, 2015 09:00PM
I know it's in the UK..

http://www.plastics4performance.com/window-kits-windscreens.html?brand=165&model=296&screen_type=577



Yes, it's a Ranger.
Xr4Ti, it is rwd and was made in Germany.
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Robert Culbertson
Robert Culbertson
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Re: Merkur rear hatch glass
January 22, 2015 09:55PM
Gobright, bring a hatch down here and some lexan. We can place it over one of the electric arc furnaces or heat treating ovens at work to heat it up! What could possibly go wrong...

If you want an oven, I can get access to a walk in composites oven. It'll fit a hatch no problem.
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Rallymech
Robert Gobright
Mod Moderator
Location: White Center Seattle
Join Date: 04/27/2008
Age: Midlife Crisis
Posts: 1,287

Rally Car:
91 VW GTI 8V


Re: Merkur rear hatch glass
January 23, 2015 08:39AM
An oven is the way to go. Apparently polycarbonate needs to be baked for several hours before it can be formed otherwise it will bubble.



Robert.

"You are way too normal to be on Rally Anarchy." Eddie Fiorelli.
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Mark
Mark Malsom
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Re: Merkur rear hatch glass
January 23, 2015 09:13AM
Some good info on preheating:

http://www.theplasticshop.co.uk/plastic_technical_data_sheets/lexan_polycarbonate_sheet_processing_guide.pdf

Also it cools very quickly so be prepared once you pull it from heat.



-Mark
www.nocoastmotorsports.net
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gripen
Paul
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Re: Merkur rear hatch glass
February 07, 2015 09:43AM
What about heating up the polycarbonate sheet with/on top of the glass in a big oven? Will it want to stick to the glass? Coat glass with something? Or just heat up the sheet, pull it out, and quickly try to form it?
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john vanlandingham
John Vanlandingham
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Saab 96 V4



Re: Merkur rear hatch glass
February 07, 2015 10:42AM
Quote
gripen
What about heating up the polycarbonate sheet with/on top of the glass in a big oven? Will it want to stick to the glass? Coat glass with something? Or just heat up the sheet, pull it out, and quickly try to form it?

My limited experience with Lexan is that you do the heating slowly or it fogs up,,
On Xratty hatch I've just gone a bit, like 1/16th thinner and it worked fine for hatch and side windows..



John Vanlandingham
Sleezattle, WA, USA

Vive le Prole-le-ralliat

www.rallyrace.net/jvab
CALL +1 206 431-9696
Remember! Pacific Standard Time
is 3 hours behind Eastern Standard Time.
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