cutting lexan

Okay, due to previous advice from members of the collective(very good advice), I had refrained from installing lexan windows in the original build of my car. Instead, spending my money and time on items that would really have an impact on making me go faster- tires, more events,etc, and that when I "ball the car up", to start thinking about lexan since it needs replaced anyway. Since then, I have rolled the car, and have available lexan that had been purchased years ago. What are the best ways of cutting, drilling and fastening this material? These are stationary quarter windows. Advice appreciated.

If they are straight cuts, its easy.

I used a plywood blade in a skill saw, but I put the blade in backwards. Cuts like butter, and leaves an acceptable finnish without burning or discoloring the lexan.

You can then use a sander with coarse paper to smooth the edges. I didn't though.

For mounting, I just used pop rivets and RTV. normal drill bits work.

To improve the look, I would put the piece in place, and trace around the inner frame. then take it out, tape off the center, and paint the outer ring black. This gives the window a more OE look, and hides the ugly frame of the window. If you paint the inside it looks much better then the outside. I can post pictures of mine if you like.

The side windows were the biggest bitch, there is a healthy curve near the top, and boy did it suck to get them to bend. The OE windows were a bit thicker then 3/16" so I was forced to go with 1/4". If you are running NASA, get 3/16", its way easier to work with.

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I Seppanen, Car #240

Here, here are some photos.



Off the car.

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I Seppanen, Car #240

yep wood blades do the job well, use painters tape on the cut line to avoid scratching the surface with a saw.

Yeah, tape over the cutting area.
I use a hand held jig saw.
Paint on the inside to give that framed look.
I prefer stainless steel button head screws. More work to install, less or similar to remove (compared to drilling rivets), allows you to tighten progressively and doesn't bend/break the lexan as the rivet tightens down.
I used regular steel ones and they got rusty over time. I'll order some small stainless steel ones from McMaster next time.
I used wing nuts on the back of mine. Most were held in place by door, few I had to hold with fingers. A few rattled loose over time, but okay.

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Grant Hughes

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NoCoast
I prefer stainless steel button head screws. More work to install, less or similar to remove (compared to drilling rivets), allows you to tighten progressively and doesn't bend/break the lexan as the rivet tightens down..

If I ever need to pull my windows, this is the route I will go. Mostly for ease of removal in the future.

I wouldn't be worried about bending or breaking lexan. The stuff is dern near indestructible other then being easily scratched. There are pictures floating around of a someone who rolled their car and blew out the rear lexan windows. They were bolted in, and it snapped all the bolts when the body wrinkled. The windows were retrieved with no more damage then a little scratching.


PS, loctite is your friend if you go with bolts.

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I Seppanen, Car #240

Make sure you drill the holes a little oversize, especially if you are using pop rivets. Otherwise when the rivet expands it will tend to crack around the hole.

I've cut plexiglass with a jigsaw and band saw without a problem.

Mirror statements here. I used a jig-saw with a fine tooth blade. Painted the inside edge black as well. I used slide fasteners to attach the passenger window if I needed to access the battery behind the passenger seat. Since I'm doing it all over for the driver's side from my STPR roll, I'm going to attach it the same way as well. Will make it easier as well to access the STI intercooler spray I put behind the driver's seat as my windshield washer reservoir/pump too.

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BillyElliot
Mirror statements here. I used a jig-saw with a fine tooth blade. Painted the inside edge black as well. I used slide fasteners to attach the passenger window if I needed to access the battery behind the passenger seat. Since I'm doing it all over for the driver's side from my STPR roll, I'm going to attach it the same way as well. Will make it easier as well to access the STI intercooler spray I put behind the driver's seat as my windshield washer reservoir/pump too.

I thought about going the slide lock route, but my windows are so high up, and oddly shaped that is just didn't seem worth it. I am not fitting my fat ass through that hole.

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I Seppanen, Car #240

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BillyElliot
Will make it easier as well to access the STI intercooler spray I put behind the driver's seat as my windshield washer reservoir/pump too.

You gonna make a metal fireproof bulkhead for that inflammable windshield washer fluid and pipes? Or did they stop with that hoo-ha?

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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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john vanlandingham

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BillyElliot
Will make it easier as well to access the STI intercooler spray I put behind the driver's seat as my windshield washer reservoir/pump too.

You gonna make a metal fireproof bulkhead for that inflammable windshield washer fluid and pipes? Or did they stop with that hoo-ha?

Whoa, there are huge amounts of highly flamable alcohol for freeze prevention. Might not blow up the car, but think of the children in antartica!

Speaking of firewalls, can a firewall be removable or does sealed mean not removable?

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aj_johnson

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john vanlandingham

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BillyElliot
Will make it easier as well to access the STI intercooler spray I put behind the driver's seat as my windshield washer reservoir/pump too.

You gonna make a metal fireproof bulkhead for that inflammable windshield washer fluid and pipes? Or did they stop with that hoo-ha?

Whoa, there are huge amounts of highly flamable alcohol for freeze prevention. Might not blow up the car, but think of the children in antartica!

Speaking of firewalls, can a firewall be removable or does sealed mean not removable?

But if there's even a one in a million chance, then we better enforce the rule and exclude violators.. Yea even unto retro-stripping them of their results!

And the fire"proof"ness is a bad joke, some OEMs that start with a "Vo" and end with a "240" have removable panels both side of the firewall but don't tell anybody or they'll add more minimum weight and a smaller restrictor!Oh NOEZ!

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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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john vanlandingham

But if there's even a one in a million chance, then we better enforce the rule and exclude violators.. Yea even unto retro-stripping them of their results!

Geez, calm down there grouchy. I have seen washer fluid burn, sorry, I wouldn't want it in a cheap plastic just right behind my seat in a race car, but some people are dumb enough to do that, so they have to have rules, and what are rules if they are not enforced?

I don't understand all the animosity towards this rule, it makes sense. My washer fluid jug is, in fact, right behind my seat. I just keep it full of water. This has the bonus of, if I have a cooling issue, I can pop the hose off the hood and stick it in the radiator and flip the switch. I am carrying around nearly a gallon of coolant and windshield spray all in one.

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I Seppanen, Car #240

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Ian S

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john vanlandingham

But if there's even a one in a million chance, then we better enforce the rule and exclude violators.. Yea even unto retro-stripping them of their results!

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Geez, calm down there grouchy.

Toute le jour calme, mec, j'ai reste calme.

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I have seen washer fluid burn, sorry, I wouldn't want it in a cheap plastic just right behind my seat in a race car, but some people are dumb enough to do that, so they have to have rules, and what are rules if they are not enforced?

I was just joking, but people were excluded--thrown out for nonsense...
whassis duff mentioned sumpin about a resevoir and with all the"panic' about anit-sub belts, I fingered I should get all panic-y too..

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I don't understand all the animosity towards this rule, it makes sense. My washer fluid jug is, in fact, right behind my seat. I just keep it full of water. This has the bonus of, if I have a cooling issue, I can pop the hose off the hood and stick it in the radiator and flip the switch. I am carrying around nearly a gallon of coolant and windshield spray all in one.

Do you keep the receipts for the water so you can prove it's water at scutineering?
You claim it's water, but how do we know its not some sooooper -secret---Suomi-soup that makes the car faster??

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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.