Back onto the doors and it was time to make the windows. These are made from LEXAN. Its a trade name for polycarbonate, but most people just call it LEXAN it seems. Again, as everything seems to at this point in time, first up was a cardboard template.
Once the shape was right, it became obvious that the actual frame itself needed modifying. The window was being held proud at the leading edge. The problem was that the frame was flat, but the window curved, thus the inner most edge of the frame was holding the polycarb off the rest of the frame. So, the frame was cut back to almost a minimum, just enough to get a nut on the back!
This wasn’t quite enough, so I then chamfered the edge aswell.
Once this was sorted, the same issue became apparent with the lower edge, so the same fix was applied.
It was then just a matter of drilling a cliquoing the window in. I plan to bolt the window in, but seal it with some silicon, but have not got the right bolts, so this will have to wait for next weekend.
I had thought that I would be able to reverse the template from the drivers door for the passenger door. However the window is actually 1/2 inch shorter and slightly a different shape, not surprising as its all handmade, so I had to make up another template. You can see below I taped in the polycarb before drilling.
Tags: Bodywork
