The 24 Hours of Lemons Forums → Lemons Tech → Lexan attaching - how to?
Wanting to replace the heavy lift gate glass with lexan and I’m looking for information on how people have successfully sealed and secured it so it doesn’t crack or leak. What thickness should be used and does it need supports?
I used a Lexan sheet from Amazon, link below.
I took the windows out of my car, traced them into the lexan and then cut one out in the same shape.
To secure it, I used bathroom caulk and sheet metal screws.
https://www.amazon.com/gp/product/B07GNM7QQW
I have used tabs and channel so I have never had to drill holes.
I've had success in the past by pre-drilling clearance holes in the lexan and then using a rivet or self drilling screw to mount the lexan. I would recommend using rubber bonded washers so that there isn't a hard metal clamping surface on a stress riser. With rubber bonded washers you should start cracks as long as you don't get cracks from drilling the clearance hole. If your worried about cracking while drilling which sometimes happens, I've also burned holes into plastic using a torch and pin punch. Doesn't leave cracks, as long as you don't care about your health!
<snip>I've had success in the past by pre-drilling the clearance hole. If your worried about cracking while drilling which sometimes happens, I've also burned holes into plastic using a torch and pin punch. Doesn't leave cracks, as long as you don't care about your health!
..Or use a soldering iron/pencil......
The Rover had a lexan windshield, we made a channel and then drilled a few, large bolt holes on the bottom with washers on both sides to prevent it from shifting up and down.
On the wagon, we use got rid of all glass but the windshield. We got some thin lexan and riveted it into place. As long as you don't drill too close to the edge, its fine.
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