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[924-76]

How I did my plexiglass quarter and door windows

I used:
- Plexiglass
- Safty goggles
- 4 clamps
- Rotary tool with cutting bit and sand barrow
- Heat gun
- 2 sand bag


I bought plexiglass from the local hardware store.
The one I used is about 1mm thinner than the glass; it was the closest one available.

1. Trace the window shape on the plexiglass.


2. Cut the plexiglass about ½ in larger than your mark, I used a rotary tool with a cutting bit.


3. Place the window with the concave side up on a table or working space.


4. Place the plexiglass on the window.


5. Heat the plexiglass with a heat gun, be careful to not overheat it.


6. Place sand bag on it and let sit for several minute.


7. Repeat step 4 and 5 until the plexiglass hold the right curve.


8. Use few clamp to hold the plexiglass and glass together.


9. Cut the plexiglass to the same size than the window, I used the rotary tool with a sand barrow.



Because the plexiglass is slightly thinner, I put a small foam band (I cut the adhesive side) inside to keep the plexiglass tight in the gasket/weather strip.




The weight difference between the glass and plexiglass is not that big, 13lbs for the quarter and door window all together.
_________________
1976 924 N/A ROW SOLD
1980 931S
1981 931 Part car RIP

[dreamgts]

Thats some nice work. Would like to do something like that to my track car project. Did you put weight on the plexi to contour it? I think its also possible to do the front sides too.

dreamgts
_________________
2 PORSCHE 924 (CURRENT PROJECTS)
2 CLASSIC CORTINAS (FINISHED)
1 CLASSIC FIAT(FINISHED)
1 CLASSIC FIAT 132 2000CC(JUST PURCHASED)
4 SUV'S
2 SEDANS
1 OPEL PANEL VAN
WIFES SUZUKI ALTO

[ideola]

Nice write up!!! Now figure out how to make the GTS-style sliders for the door windows...
_________________
erstwhile owner of just about every 924 variant ever made

[924-76]

[Dutch924-racer]

How much weight did you save exactly ?
_________________
937 trackday car
Series 2 engine
951S turbo and intercooler
Fast road camshaft
Forge recirculation valve + boost controller

[924-76]

13 lbs with the 4 fiberglass window (2 quarter + 2 door)
_________________
1976 924 N/A ROW SOLD
1980 931S
1981 931 Part car RIP

[Dutch924-racer]

did you use 3mm windows ?
_________________
937 trackday car
Series 2 engine
951S turbo and intercooler
Fast road camshaft
Forge recirculation valve + boost controller

[924-76]

Yes
_________________
1976 924 N/A ROW SOLD
1980 931S
1981 931 Part car RIP

[tyfighter123]

Those look awesome way to go!!!
_________________
Porsche 924 1977 N/A
Mustang GT/CS 2007
Porsche 924S 1987 (parts car)(cut up and recycled)
Porsche 911S 1976
Porsche 931 1980
Porsche 931 1980 (parts car)