We can now replace windows in H2 with lexan! H1 guys, Were did you get your lexan for your rear and side windows? also how think should it be? Thanks!

 

Walter, since you, David, and I all drive the same cars, perhaps we could find someone to custom make the rear and side windows? Would you be interested?

 

Yes! I would be. The less fab work I have to do the faster I can get the car ready! count me in.

 

When I get a chance (the next few weeks are going to be super busy), I'll contact a couple of places I know of that do custom lexan windows. I'm not sure of the cost, though.

 

I bought scratch-resistant Lexan from mcmaster.com. Made a cardboard template and cut it out with a sabersaw. It's cuts and machines really nice.

 

buy it from your local sign or plastic shop, and then use the OEM window as a template.


The FAL stuff is really really expensive, it is very worth it to do it yourself.

 

The rear window on the Prelude appears to have a compound bend in it. What's the best way to get around that? Can you gently heat the lexan/polycarbonate to "mold" it to that shape, or do you leave it flat and force it to fit by riveting it in place?

The side windows don't appear to be a problem as they're flat.

Do most people just rivet them in place and seal them, or install them like OEM windows with the trim and all?

 

Don't really worry about it. Just take it and start pop riveting from the center out. That is how you get your bend. Don't forget to strap it down.

I don't even think most people seal them.

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by 117 &raquo;</TD></TR><TR><TD CLASS="quote">The rear window on the Prelude appears to have a compound bend in it. What's the best way to get around that? Can you gently heat the lexan/polycarbonate to "mold" it to that shape...?</TD></TR></TABLE>
No. I took a plastics class at the local JC for that specific purpose and tried it in a full sized oven. Turned to chit even with the instructor helping. Lexan is really tough to bend even under ideal conditions. Its hopeless without them.

I've heard acrylic is much easier to work with, but I have not tried it.

If you want NICE Lexan, the FAL stuff is great. It might seem expensive if you compare it to raw lexan sheets, but its a bunch cheaper than getting custom lexan from Shields or any of the other race industry suppliers. Last time I checked, FAL would do custom orders for cars not in their catalog if you're willing to organize a bulk/group buy of 10 units or more and provide them with two pieces of OEM glass.

If anyone wants to get rolling on an EF hatch back glass order, let me know.

 

when did the rule go into effect? any others i should no about, like headlights or hood

 

Effective immediately: http://www.nasaforums.com/view...20579

 

http://www.nasaforums.com/view...20579

This rule addendum was just released yesterday.

Regards,

Sam

 

thawley-pm'd

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by thawley &raquo;</TD></TR><TR><TD CLASS="quote">

I've heard acrylic is much easier to work with, but I have not tried it.</TD></TR></TABLE>

I wouldn't recommend Acrylic...the stuff shatters something awful if tweaked the wrong way. Not to mention it's illegal in every race series I know of.

 

yea, reading up on the differances it seems like its not what you wanna use in a racecar

 

Scratch-resistance Lexan cannot be heat-formed, though apparently the regular stuff can be. Compound bends are probably impossible, but you can simply turn it into a single-plane bend. Get a big cardboard sheet and trim it to size, then cut out the Lexan. Put it exactly in the center and place the first rivet, then work your way outboard, using the rivets to bend it; that's how I did the rear window in my Mini. The fasteners that look like rivets are actually tiny Allen head buttonhead screws. Got them from mcmaster also:




Modified by kb58 at 7:05 AM 2/22/2008

 

how thick? 1/8" ?

 

I had my car backhalfed in Flex a lite... i could not have been happier. costly yes, but perfect fit with compound bends. That being said... kb58's work looks beautiful

 

Corey ran aluminum strips down the rear lexan on my 4th gen Prelude. I've seen other cars with it too. Is that to prevent catrastrophic failure? Anyone had an issue with Lexan blowing out?

 

Sure it can happen... but mine never did, and it's huge piece. Had it over 130 many many times, a credit to the installer. but I would put a center piece for a track only car

 

Don't use acrylic on your cars people lol

They sell Lexan at home depot these days, but don't pick up the acrylic by mistake lol.

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by thawley &raquo;</TD></TR><TR><TD CLASS="quote">
No. I took a plastics class at the local JC for that specific purpose and tried it in a full sized oven. Turned to chit even with the instructor helping. Lexan is really tough to bend even under ideal conditions. Its hopeless without them.</TD></TR></TABLE>

Did you guys try thermo forming it?

I too took a plastics class and we thermoformed more than one type of plastic. I asked about doing polycarbonate (lexan) and the teach said yeah no problem.

We thermoformed PET sheets all the time in there. does anyone think PET sheets would work for this? FYI PET (or PETE) is what pepsi and aquafina bottles are made out of

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by niterida &raquo;</TD></TR><TR><TD CLASS="quote">

Did you guys try thermo forming it?

I too took a plastics class and we thermoformed more than one type of plastic. I asked about doing polycarbonate (lexan) and the teach said yeah no problem.

We thermoformed PET sheets all the time in there. does anyone think PET sheets would work for this? FYI PET (or PETE) is what pepsi and aquafina bottles are made out of</TD></TR></TABLE>

RC car bodies are lexan so I'm pretty sure you can thermoform replacement glass

http://www.rcuniverse.com/foru...m.htm

 

I got my stuff from NOPI and it was FAL... Molded to fit.

 

<TABLE WIDTH="90%" CELLSPACING=0 CELLPADDING=0 ALIGN=CENTER><TR><TD>Quote, originally posted by Chris F &raquo;</TD></TR><TR><TD CLASS="quote">Corey ran aluminum strips down the rear lexan on my 4th gen Prelude. I've seen other cars with it too. Is that to prevent catrastrophic failure? Anyone had an issue with Lexan blowing out?</TD></TR></TABLE>

You can "brace" the lexan with aluminum/steel strips, but unless they are actually attached to something solid they don't do much.
I have a hatch off of warren ****'s old ITR and he too ran strips down the middle...they really don't do anything to stiffen the lexan so it flexes less. The stuff he seemed to use is extremely thin.

Technically I think they're shold be a rule to brace the stuff or at least run a set of fasteners on the outside besides just rivets to prevent the possibility of it "blowing out" unless you are using FAL stuff which glues in like glass because of the coating they put on the inside.