Fitting Polycarbonate / Lexan Windows


B

Blair

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Jan 2, 2015
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Hey guys,

So I had a full set ( front and rear) polycarbonate windows arrive the other day for the race car (EK3).

Ive held it in the channel where the window used to sit, and it fits real nice. My big question is how the hell do they attach !

Id really like to get a few proper fixings in there (nuts and bolts, or pot rivets) before applying a bond like tiger seal. If possible id try to use as little bond as possible, if I have to reshell the car id like to be able to remove them again.

Any help,advice or pictures of how you have fitted it would be greatly appreciated
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Many Thanks

Blair
 
Fronts bolt in, rears and tailgate will need to be bonded and bolted in. Still dead easy to get the rears out if you need to, but better safe than sorry whilst your driving it. I got a local window fitter to bond my rears in whilst he was refitting my windscreen. The stuff they use is mega if you know any.
 
When i bought the kit i purchased the "Window Bonder" for about £8, with the intention of using it for the rears.

My problem with the front is that i could probably find a few places to put bolts through around the top and side of the door. But its the bottom of the window I'm really struggling with , there's a huge void and it just seems to be flapping about in there, with not a lot holding it on.
 
Self tapping screws are your friend here :)

The door is screwed to the window and the window is screwed to the outside window trim (obviously bit straight through it ha ha ). This keeps it all nice and together to try and stop water just running straight into the door
 
I got a window guy to do rears and back and he is used to bonding polycarb into funeral vehicles, so has the right primer.

I still have elec window mechs in the front...but not for long.
 
Con you make a spacer or two for the void? Just a small tube of anything with the bolt through the middle should hold it snug against the outer skin on the door?
 
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That would definitely work if I had more door left. The way I've done it gives some solidity to the top of the door skin as well. Keeps it all nice and together
 
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I made the mistake of cutting a HUGE hole in the door skin, then decided against it, and painted another door and put it on. The weight i cut out was negligible compared to what i was going to have to fill it back in with.
 
I know that feeling :)

Not on the door, on the boot floor :-(
 
Been a while since i updated this. Since the last post I've got another door, this time I'm not going to cut the door skin. Whilst a flat panel looks nice, its really not saving me any weight, and if the lock mech shits out on me then at least i can still get to it.

In terms of fitting the windows. Ive opted to use Rivnuts. Ill place 3 rivnuts down the side of the window and 2 along the top. Then use a couple of bolts to just "push" against the bottom of the window.

Ill post pics soon, im having a crack this weekend.
 
Looking forward to the pics, if I go full retard on the civic I'll end up with poly windows lol
 
Ill be sure to get them up.

It wasn't the glass i was worried about loosing, it was the window motor and regulator, that's the heavy bit. The only sensible replacement is to put poly windows in, so that's the route I've had to go down.
 
I just bolted and riveted them in on my rally car. one thing I though Id mention if no one hasn't yet, they scratch ridiculously easily! so be careful, just cleaning with a soft cloth and water scratches the bloody things
 
Here they are then as promised. I went a bit overkill, the main goal was to have something properly secured, but easily removable if necessary. I used around of 9/10 riv nuts per door (about £6 worth total).
The top and side are bolted in with hex head bolts and washer. The bottom of the window are being 'pushed against' with the same method, but if put a little section of windscreen washer hose over the end of the bolt, to push softly against the window.

Here you can see the riv nuts inserted. I just drilled these with a series of bits and then the 'Christmas tree' bit. I'm using M6 Rivnuts.

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Then with the window in and bolted up without any trim.

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And then the final product with the OEM trim and rubbers back on.

IMAG0741.jpg
 
Good job! I ended up using the Gold Honda self tapers that you find when you remove the interior bits from the car, I took the easy route and drilled a 3-4mm hole into the metal and through the lexan and screwed it into place

My car is an integra and I managed to cut the window seal and fit it with the window at the top, I also used the same screws at the bottom of the window and drilled into the bottom seal to keep it secure
 
Cheers Guys, I searched high and lower over the internet for a few decent pictures, at least there here now :). I think I'm going to put a little bead of silicon around the window, just for a little something extra.
 
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