QUOTE(wndsrfr @ Oct 28 2016, 07:47 PM)
QUOTE(stugray @ Oct 11 2016, 01:58 PM)
I made mine from a sheet of 1/4" lexan.
Made a router template from the old windshield, rough cut it with a jigsaw, then routed it with a laminate trim bit.
Then I installed riv-nuts to screw it down around the perimeter.
If you want to go that route, I could provide detailed instructions and pictures.
I'm interested in a bit more info....my glass is so pockmarked & sandblasted that it's dazzling in bright sun--dangerously so. I'm thinking of doing a lexan replacement but need the encouragement of some pics & tips to get going on it.....
I made a masonite template from the old windshield and verified that it fit the opening:
Traced the template onto the lexan:
Cut it outside the line with a jigsaw:
Routed it to size with a laminate trim bit and the masonite template as the guide:
The masonite template had holes drilled to transfer to the window frame.
Then I drilled each out to accept a floating rivet-nut:
The tool had to be modified to fit in the windshield track area:
Then I put self-adhesive black neoprene gasket in the track and screwed the windshield down:
I ended up putting one more insert in each lower corner after those pics