Merkur rear hatch glass

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.

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Robert.

"You are way too normal to be on Rally Anarchy." Eddie Fiorelli.

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

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Grant Hughes

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.

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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.

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.

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.

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Grant Hughes



Edited 1 time(s). Last edit at 01/21/2015 01:47PM by NoCoast.

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!

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Robert.

"You are way too normal to be on Rally Anarchy." Eddie Fiorelli.

I know it's in the UK..

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

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Yes, it's a Ranger.
Xr4Ti, it is rwd and was made in Germany.

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.

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.

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Robert.

"You are way too normal to be on Rally Anarchy." Eddie Fiorelli.

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.

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-Mark
www.nocoastmotorsports.net

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?

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..

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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.