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Thread: Lexan Windshield question

  1. #1

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    Lexan Windshield question

    Went out to drive the Mk4 this weekend and discovered a large crack in my windshield....dang. I can't say I was too surprised, but with less than 1000 miles on the car I'm a bit bummed.
    I know a bunch of guys have gone with Fast Freddie's windshield, and that is my first choice, but their site shows they are out of stock and I can't see to get in touch with anyone there.
    With that I may have to replace it myself with 3/16" Lexan (MR10 or AR2 type). For those of you that have done this, I and was wondering what type and size of rubber gasket material you used? A link would be most awesome. Or, can the glass windshield gasket be re-used?

    Dave

  2. #2
    Senior Member CraigS's Avatar
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    I think the lexan is thinner than the glass.
    FFR MkII, 408W, Tremec TKO 500, 2015 IRS, DA QA1s, Forte front bar, APE hardtop.

  3. #3
    Mr. Congeniality mikeinatlanta's Avatar
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    I have a Fast Freddie's windshield kit. pm if interested, but not a motivated seller so will be retail price, not get rid of it cheap price.
    MKII "Little Boy". 432CI all aluminum Windsor. .699 solid roller, DA Koni shocks, aluminum IRS, Straight cut dog ring T-5, 13" four piston Brembos, Bogart wheels. BOOM!

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    I had a 3/16 scratch proof lexan cut using the glass a a template. I had it done by a local shop.

    The glass is 1/4" thick but I still reused the glass rubber gasket for the 3/16 Lexan.

    The cost was probably half of Fast Freddie's.

  5. #5

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    Can you think of any reason not to use 1/4” Lexan with the original gasket?

  6. #6
    Senior Member AC Bill's Avatar
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    Quote Originally Posted by CalR80 View Post
    Went out to drive the Mk4 this weekend and discovered a large crack in my windshield....dang. I can't say I was too surprised, but with less than 1000 miles on the car I'm a bit bummed. Dave
    Did you follow the instructions for installation in the FFR manual? Glass might be covered under warranty from FFR.

    If you get a new glass from them, ignore their installation instructions, and read all about the proper way to do it on this, or the FFCars forum.

  7. #7
    Senior Member CraigS's Avatar
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    Quote Originally Posted by CalR80 View Post
    Can you think of any reason not to use 1/4” Lexan with the original gasket?
    Other than cost? No I can't. Well maybe. I wonder if it's too stiff to make the slight curvature to fit into the frame. I know the side windows on my APE top are very stiff
    FFR MkII, 408W, Tremec TKO 500, 2015 IRS, DA QA1s, Forte front bar, APE hardtop.

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    Quote Originally Posted by CraigS View Post
    Other than cost? No I can't. Well maybe. I wonder if it's too stiff to make the slight curvature to fit into the frame. I know the side windows on my APE top are very stiff
    That's the reason why I used 3/16". It's not like it needs to be water tight.

  9. #9
    Senior Member Mesa Mike's Avatar
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    Yes, thinner
    I replaced my first windshield with a lexan one. Took the old windshield and made a stencil and had a glass company cut for me. No tint. Later I returned to the glass. I prefer the glass. Depends if you are going to track it. If track, lexan.

  10. #10

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    So here it goes....

    Thank you all for your replies. i decided to give Lexan a try using the original glass windshield gasket. First I removed the windshield and took off the bottom channel. The rubber gasket came off pretty easily but there was a bunch of sealant goop that had to be cleaned off the old windshield and gasket using paint thinner and elbow grease.



    Next I purchased a piece of 3/16" Makrolon AR-2, the abrasion resistant stuff. With a little help from my daughter and her friend I had them hold up the new Lexan to the old windshield as I traced the shape onto the AR-2.



    The guy at Tap Plastics recommended a jig saw with a course blade to cut the AR-2. Before the cut I put some masking tape over the plastic coating where the base of the jig saw would ride over just for some added protection. The jig saw worked great. Afterward the cut I sanded the edge with some 120 grit.



    I trimmed back plastic coating about 1/2" around the perimeter of the new windshield on both sides and placed the old gasket material around the edge and then used some dishsoap on the gasket to ease it back into the frame. A second pair of hands is really good at this point and my son's were available so he got drafted. The bottom frame piece went on next and then screwed in place. The new Lexan is 4.58mm thick while the glass was 5.66mm so it was pretty easy going into the frame but not sloppy once it was buttoned up. Finally the windshield went back on the car with the help of my wife and son. The clarity of the Lexan is great and I don't anticipate having to mess with this again.


  11. #11
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    Looks great! Nice job. Thanks for the write up and pics.

  12. #12
    Senior Member Dave Howard's Avatar
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    Great job. Wish I had thought of doing that (making your own that is). I went the Fast Freddie route and have no regrets and it has bee worry free since installation.

  13. #13
    Senior Member chrisarella's Avatar
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    Dave, what did it end up costing you?
    {EDIT} Never mind.... I just saw on Facebook you said $150.
    Chris
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  14. #14
    mcwho's Avatar
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    Is anyone selling these Lexan Windsheilds precut?
    Baghdad Bob

    Complete Kit ordered Feb 2009, Delivered July 2010, serial @ 7287, Power Brakes, Power Steering w HEIDTS Valve, Hydralic clutch, 15" Wheels, BFG Tires, 331 stroker w Edelbrock Performer RPM Heads, Edelbrock Performer Air Gap Intake and Quick Fuel 650 carb. IRS w 3.27, TKO-600. FFMETAL Firewall Forward, FFMETAL Dropped Battery Box in Trunk, Enlarged Passenger footbox, Breeze Cubby storage, Breeze Seat Brackets, Herbs Door Panels.

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    Quote Originally Posted by mcwho View Post
    Is anyone selling these Lexan Windsheilds precut?
    http://www.fastfreddiesfabrications....p?id_product=1

  16. #16
    mcwho's Avatar
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    awesome, thanks
    Baghdad Bob

    Complete Kit ordered Feb 2009, Delivered July 2010, serial @ 7287, Power Brakes, Power Steering w HEIDTS Valve, Hydralic clutch, 15" Wheels, BFG Tires, 331 stroker w Edelbrock Performer RPM Heads, Edelbrock Performer Air Gap Intake and Quick Fuel 650 carb. IRS w 3.27, TKO-600. FFMETAL Firewall Forward, FFMETAL Dropped Battery Box in Trunk, Enlarged Passenger footbox, Breeze Cubby storage, Breeze Seat Brackets, Herbs Door Panels.

  17. #17
    mcwho's Avatar
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    I have the fast freddies kit, and have re checked my measurements with the windsheild off. Wondering if anyone else has done the measurement of the windsheild support arms. I measured the inside and outside level surfaces with laser devices used for wheel alignments. apparently the two that i have are not parallel and i believe that they should be. The edge at the top of the arm does or did not alingn up correctly and dont understand why this would happen as they are connected to the frame.

    Before I mount the Lexan windsheild, I want to verify whats wrong here so that I dont have another cracked windsheild. If i dont get much esponse here I'll start a completely new post, but I believe that it is related.

    I did start a new thread here...

    https://thefactoryfiveforum.com/show...s-not-parallel
    Last edited by mcwho; 04-01-2019 at 10:42 AM.
    Baghdad Bob

    Complete Kit ordered Feb 2009, Delivered July 2010, serial @ 7287, Power Brakes, Power Steering w HEIDTS Valve, Hydralic clutch, 15" Wheels, BFG Tires, 331 stroker w Edelbrock Performer RPM Heads, Edelbrock Performer Air Gap Intake and Quick Fuel 650 carb. IRS w 3.27, TKO-600. FFMETAL Firewall Forward, FFMETAL Dropped Battery Box in Trunk, Enlarged Passenger footbox, Breeze Cubby storage, Breeze Seat Brackets, Herbs Door Panels.

  18. #18
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    Lexan won't crack.

  19. #19
    Senior Member CraigS's Avatar
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    Yep the arms are not a real well done design. They don't really mate w/ the w/s frame very well. All you can do is install the screws and let them self align as well as they will. Then bend the bottoms to fit the car. Usually they need a bit of a twist and also a small bend. A way to get them close is install them to the windshield and then lay the w/s on a table w/ the arms sticking out over the edge. The bottom corners of the w/s should be exactly at the edge of the table. The bottom portions of the arms should be parallel to each other and at 90 deg to the table edge looking down from the top. Looking in at the end of the arms they should be at 90 degrees to the floor. A quick drawing
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    FFR MkII, 408W, Tremec TKO 500, 2015 IRS, DA QA1s, Forte front bar, APE hardtop.

  20. #20
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    Has anyone thought about making a windshield about half as high as the stock? I think the look would be interesting- but you might need goggles for driving. I'm thinking shortened side frames and no top frame.

  21. #21
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    I'm considering a half-height for the track and have looked at it on a previous car. I liked it. Not sure I'd want it on the street, goggles may be needed but that would depend on how tall you sit in the seat. In a discussion with an engineering friend he thought that there would be a significant reduction in drag, the appeal for track use.

    For those that have contributed to this discussion I really appreciate the info on DIY Lexan.

    Jim

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  23. #22
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    Looks really good! i've read so many threads on the windshield that i'm sorta half expecting it to crack and you've inspired me to go this route if it does. I installed/un-installed my windshield at least 20 times as a bent the arms / rechecked / etc. In the end, i machined (2) aluminum spacers for the passenger side so i wouldn't put undue bending stress on the arms (and consequently the glass). Reason - it was totally impossible to get them parallel (at least for me) so i made the drivers straight and made up the difference on the passenger side. So far, so good- i guess time will tell

  24. #23
    Senior Member CraigS's Avatar
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    Way back in the day Fast Freddie used to run his FFR on the track. He made a small half moon shaped w/s for the track. I forget the exact numbers but he dropped his lap time by somewhere in the full second range.
    FFR MkII, 408W, Tremec TKO 500, 2015 IRS, DA QA1s, Forte front bar, APE hardtop.

  25. #24
    Senior Member Packer fan's Avatar
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    Does anyone know if you can put rainex on the lexan without scratching it, and does it work as well as on glass?
    Last edited by Packer fan; 04-03-2019 at 10:02 PM. Reason: Spelling correction
    Mk4 ordered 1/3/18, IRS, Coyote, T56 Magnum

  26. #25
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    A couple of articles to read.

    Helicopter Windshield Maintenance - no discussion about Rain-x but a good read
    https://helicoptermaintenancemagazin...8230;-and-pork

    Rain-x specifically for plastics and lexan
    https://www.rainx.com/product/plasti.../#.XKV-PsIpCpc

    Discussion here in 2016
    https://thefactoryfiveforum.com/show...er-suggestions

    George

  27. #26
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    No Lexan windshield yet, but will.

    I've run a 3M plastic shield over glass, a product specific for the purpose and it did a good job of minimizing etching and rock chips. I used RainX on this all of the time, worked well. I would expect RainX to work with Lexan but there may be a specific variety for Lexan.

    So here's what I found.
    https://www.rainx.com/product/plasti.../#.XKYRA5fsY2w

    I do drive in the rain, RainX certainly helps. Put it on the inside too.

    Jim

  28. #27
    mcwho's Avatar
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    Quote Originally Posted by mcwho View Post
    I have the fast freddies kit, and have re checked my measurements with the windsheild off. Wondering if anyone else has done the measurement of the windsheild support arms. I measured the inside and outside level surfaces with laser devices used for wheel alignments. apparently the two that i have are not parallel and i believe that they should be. The edge at the top of the arm does or did not alingn up correctly and dont understand why this would happen as they are connected to the frame.

    Before I mount the Lexan windsheild, I want to verify whats wrong here so that I dont have another cracked windsheild. If i dont get much esponse here I'll start a completely new post, but I believe that it is related.

    I did start a new thread here...

    https://thefactoryfiveforum.com/show...s-not-parallel
    Quote Originally Posted by CraigS View Post
    Way back in the day Fast Freddie used to run his FFR on the track. He made a small half moon shaped w/s for the track. I forget the exact numbers but he dropped his lap time by somewhere in the full second range.
    Way Way back innthe day there was a track called "Brooklands" and some "Brooklands style" winscreens were developed. They are the Half moon shape and served the racing car guys purposes.

    see link
    https://mossmotors.com/racing-screen...hoCVU4QAvD_BwE
    Last edited by mcwho; 04-07-2019 at 01:44 PM.
    Baghdad Bob

    Complete Kit ordered Feb 2009, Delivered July 2010, serial @ 7287, Power Brakes, Power Steering w HEIDTS Valve, Hydralic clutch, 15" Wheels, BFG Tires, 331 stroker w Edelbrock Performer RPM Heads, Edelbrock Performer Air Gap Intake and Quick Fuel 650 carb. IRS w 3.27, TKO-600. FFMETAL Firewall Forward, FFMETAL Dropped Battery Box in Trunk, Enlarged Passenger footbox, Breeze Cubby storage, Breeze Seat Brackets, Herbs Door Panels.

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