California top to Lexan panel?

[pcalahane]

Okay, so my plan is to remove the heavy and slightly rusty framed Folding top and put in a tinted grey Lexan panel.

Thoughts? Ideas? How-to description?

I know it defeats the purpose of buying and owning a California edition, but I would love having a glass (lexan) roof.

[3.2TI]

Go for it, I thought of this myself once mine goes, or you can always get a manual one made like old bugs.

[pcalahane]

What do you mean manual? Like with a crank? I've thought of that and for now think that most of the same issues would persist. I need something to get rid of most, if not all, my problems. Plus looking up at that BIG opening as all lexan and clear would be so sick. Plus it would be lightweight and remove unneeded weight from the top of the car.

I'm thinking of ways to waterproof it and to get it to bend both ways the roof curves.

[3.2TI]

http://www.jbugs.com/product/C-671-S...bug-headliners

image is from : http://www.vantagesportscars.com


These seem to be more durable and easier to fix.

[pcalahane]

Realistically it's the same product but with a latch. Not sure that would be worth it. I could just disable or remove the motor and have the same effect. Push/pull motion. Does anyone have experience putting on lexan windows? I'm sure or would be close to the same for the top.

[pcalahane]

Anyone have experience with making lexan waterproof at the seams? Anyone using lexan windows? Anyone already do something like this? Come on guys, lets get creative.

[pdxmotorhead]

I would make the plastic fit in the hole with a flange on the bottom side, then use some silicone adhesive to glue it in. I'd then cut an aluminum frame from 3/32 flat stock and fit it on the outside, once the size is right have a bud who's a ninja at TIG welding weld it together at the corners, drill through the plastic and use chicago screws to clamp the AL frame to the roof through the plastic. Use window adhesive under the AL trim piece to seal it up.(Comes in a sticky rop from most auto parts stores. You could have ht eAL powder coated after welding as well as tapering it with a belt sander to make it more aerodynamic.

Note, I've built a lot of race car windshields, the plastic needs to be > than 1/8 in thick or the wind will flex it too much. A lexan window is only slightly lighter than glass. YOu may need a stay on the under side of the glass to keep it from flexing too much...

Cheers
Dave

[pcalahane]

Okay, that sounds like a lot of work... I figured if I welded in aluminum lip on the underside and had counter sunk bolts on the top every couple inches (3-4??) it could force the lexan to flex in the correct way. Also keep it aerodynamic with everything staying flat on the top. Then the only concern would be waterproofing it. What if I used a rubber window seal with silicone to adhere everything together keeping it watertight.... Would that work as well? I feel like it can be done more at home rather than paying a tig ninja to help. Lol

[pdxmotorhead]

I was thinking weld the frame so its not got a gap and looks better..

Any boat motor repair shop can make the welds, its not that bad.

What I described is how I've done lexan wind shields in the past the look decent and don't flutter... If you drill through the plastic to hold it down directly to the roof, I'd bet you crack the material when driving. Lexan/Polycarbonate don't take well to compression or stretch.. When you do a NASCAR style plastic wind shield you use larger plastic fender washers and drill bigger holes so there is room for the window to expand and contract with out stress.

Thats why I suggested some kind of clamping arrangement that allows the window to move..

Good Luck!
Dave

Silicone is a not a a great sealer in my opinion, I've had more problems form prior repairs dependent on silicone than the rope sealant for factory wind shields. that stuff takes no prisoners.

[pcalahane]

Ok, I'll talk to a couple of the local shops and see what they can quote me. Thanks for all the info Dave. I really appreciate it. I don't know why we don't have a knowledge base on lexan windows. I mean we have enough track guys that it should be covered somewhere. I've always used carbon panels but with regular glass. If this works, I may swap out all my glass for lexan (except my windshield). I like the classic mini look of fixed windows with a sliding panel. So clean looking and light weight.

[pdxmotorhead]

In road racing very few classes even allow plastic windows... Probably why its not well documented.. I learned on planes and boats from other side jobs and applied it to the race car..

I thought of another option, you could glue a "rim" around a piece of lexan to keep it from popping out of the top and screw the aluminum from the top down.. The lexan glues to itself like crazy...

Dave

[pcalahane]

Oh ok. I wish there was pictures. I am currently thinking of trying it out of home depo lexan and a trail and error method if the shops are too expensive. Lol

[pdxmotorhead]

There are plastic specialty places that are more economical and sell all the glue and proper polishes for working on plastic, as well as the stuff and information on forming and bending it if needed., They can also assist in figuring out how to mount the piece. Check out "Wicks Aircraft" and "Aircraft Spruce and Specialty" as well.


Dave

[pcalahane]

So I had an idea, if we look at our rear 1/4 window, we see that it's waterproof because of the intense pressure holding it in place by the fastener. What if, I was to mount 4 fasteners like what's on the rear windows on each corner with a rubber strip between the lexan and the metal of the roof? Could it be possible that it might hold it against the rubber hard enough to make it waterproof like the side windows?

[pcalahane]

So the top is almost off and it's time for me to make a decision. My cr is currently black, but it definately could use a respray. So originally I was thinking changing the color of the whole car to white, but then I thought of something I feel is a cool concept but maybe stupid if executed. I am thinking of respraying the car black again and powder coating my contours, kidney grill chrome rings and side mirrors Kawasaki racing green. The part I am not sure about is if I paint the roof green too would it be too much? I have to reprint the top before I put in the lexan so this decision needs to happen within the next couple days. Anyone want to put in their $0.02?