The next item is make a cardboard template to size the lexan window. I added a one half
inch thick rubber onto the aluminum strips to place the position of the cardboard into the final location
for the lexan window. If you do not space the cardboard to the final position the lexan will be short
if there is any curve to the window. Make sure you place a location mark on the cardboard and somewhere on
the car below the windshield, then transfer this mark to the lexan before you cut it. This will give you
an exact location side to side for the positioning of the lexan before you start drilling holes. I used a saber
saw with a tungsten carbide gritted blade, also from Parkrose. Mark the lexan with the cardboard form and try to
keep the edge smooth as you mark it. When it is being cut, go slow, this will give you more time to make
direction adjustments.
Once you have the lexan cut, fit it to the window and do any trimming now. When you have
a good fit and the lexan is spaced out to the final position, find the mark and locate the lexan side to side.
Everything looks like it will fit?? Now it's time to paint a black border around the edge, this helps to
hide the nuts and tape on the inside. I used a one and half inch border ( on the inside ), yours might be smaller. Peel back
the covering and use masking tape to lay out a border around the lexan. Cover the lexan good, do not get
overspray on it. When you get ready to paint, I used semi-gloss black spray paint and you have to heat the
lexan with a hair dryer to warm the plastic or the paint will not stick to the lexan!! Let it Dry!!
Now figure out the bolt spacing, I put a bolt ( 1/4 x 20 by one inch coarse button socket cap screws - black ) every four
inches across the lexan windshield. I found the center of the car and started two inches on each side of this
location. Drill these two holes on the bottom and top of the lexan and make sure the lexan is located correctly
and insert bolts in these four locations with a lock washer and nut, tighten, snug fit. Now drill a hole in the pattern
like a manifold torque sequence, top left, bottom right, top right, bottom left and insert a bolt and snug tight.
Work your way side to side across the windshield until you have the lexan bolted down all around.
If you take a little time and read what I have to say and think about what I said,
you might not have to buy that other side of the sheet.
CHECK IT OUT!!
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