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Replacement LEXAN Rear Quarter Windows |
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Posted: May 24, 2004 Last Revision: September 2, 2007 |
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After breaking one of the rear quarter windows I thought it might be best to use something that won't break quite as easily again. Plexiglas or something along the lines is what I wanted to use. After a little research I decided to use LEXAN(tm). The beauty of LEXAN is that it is available at the local Do-It-Yourself mega store (HomeDepot, Lowes, etc.) at low cost. |
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The main challenge with LEXAN is how to cut it. I
used a Dremel with variable speed and cutting bit.
At the lowest setting (about 5000 rpm) it barely worked, but
it isn't the fastest method (should be OK for the home
mechanic). Higher speeds will melt the material instead of
removing it with the cutter bit. I used a router guide with the Dremel to better guide i.e. along a fence (such as a piece of angle iron clamped to the dinner table). Besides LEXAN, there are other products, such as PlexiGlass, Lucite, and PETg. Due to the complexities associated with material science, I will not compare and contrast these various non-mineral glass window replacements. |
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Remove all the broken glass. This is the nasty part. |
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Use Duct Tape and a trash bag. Tape trash bag to cover opening. Done! Or... |
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First remove the interior (plastic, etc.) Remove the original glass window(s) using the wooden wedges. Carefully work the wedges into the window (rubber) seal by pushing the window outwards. [large image] |
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Same as above.
[large image] |
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Glass removed. A helper should hold the glass so it won't accidentally fall creating a mess (and loss, since used glass can be sold on eBay to cover some of the project's costs). |
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Here the one remaining rear quarter glass window acts as a template. Attention must be paid to which side of the LEXAN is the outside. One side is usually treated for better UV resistance. |
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The LEXAN sheet is propped up to match the curvature of the original glass. |
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Dremel with router attachment in action. The angle iron serves as a fence for straight cuts. |
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One replacement window is cut. Some smoothing of the edges with sanding drums, and it should be ready for installation. |
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The protective film has been removed and the replacemnt window sits now in the rubber window seal. LEXAN scratches easily and therefore a large beach towel helps to prevent scratches during preparation. |
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With the help of the water soaked and soaped twine, the replacement
window is ready to be reinstalled. Pull the twine to fold the rubber
lip over the sheet metal. Actually not hard to do at all, even alone.
[large image] |
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Same as above seen from the outside of the vehicle.
[large image] |
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Driver side replacement window installed.
[large image] |
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Passenger side replacement window installed.
[large image] |
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This was a fairly straight forward procedure once the cutting problem was
solved (using the Dremel with router attachment). Otherwise, the main
considerations are as follows:
If I had more time, I might have ordered a sheet of 1/4" thick tinted MR10 scratch resistant LEXAN. But it is not much of an issue either with the way it is. I might replace my '97 (2-door) XJ with LEXAN windows, since the large quarter panel windows of a 2-door XJ are far more exposed to damage. In this case, I am pretty sure I'll get the 1/4" bronze-colored LEXAN (MR10). |
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All Rights reserved. Photos: Andreas Ritterbusch www.madxj.com |
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