How to Make and Install the Perfect Fitting Lexan Windshield in Your Street Stock Race Car
Table of Contents
- Introduction
- Tools Needed
- Preparation
- Creating the Pattern
- Cutting the Lexan
- Fitting and Installing the Windshield
- Conclusion
Introduction
Installing a Lexan windshield in your Street Stock race car can significantly improve safety and performance. This guide will walk you through the process, ensuring a perfect fit every time.
Tools Needed
- Ball Peen Hammer
- Dimensional Cardboard (available at Lowe’s or Home Depot)
- 3/16” Drill Bit
- Drill
- 3/16” Clecos
- Duct Tape
- Lexan
- Jigsaw with Fine Tooth Blades
- Fine Point Sharpie
- Wire Brush Attachment for Drill
- Clamps
- Coarse File or Rasp
- Razor Knife
- Heat Gun
- Acetone
Preparation
First, remove the old windshield glass entirely. Use a razor knife to cut any urethane remaining in the windshield track. Once you have removed as much as possible, attach the wire brush to your drill and clean down to the bare metal. After brushing out all the urethane, clean the track with acetone to remove any remaining dirt and debris. The track needs to be free of irregularities so that when the new windshield is riveted in place, there are no protrusions pushing against the Lexan, which could crack it and ruin your work.
Creating the Pattern
Next, layout the dimensional cardboard so it hangs over each A-pillar and extends higher than the roof edge. Due to the curvature of the windshield, make the piece several inches larger to allow for trimming. Tape the dimensional cardboard to the centerline of the windshield opening near the roof edge. Use additional tape along the roof edge to hold the cardboard in place.
Then, take your ball peen hammer and, using the rounded side, press it firmly against the cardboard to trace the windshield opening. This will leave a witness mark on the cardboard. Trim around the cardboard following the witness mark precisely.
When you have finished cutting out the pattern from the cardboard, tape it to the Lexan blank for your windshield (leave the protective coating on the Lexan during this process). Trace the pattern onto the Lexan with a fine-line sharpie.
Cutting the Lexan
Once you have the perfect tracing on the Lexan, support the Lexan on a large flat table. Plywood on sawhorses will work if you don’t have a table. Support the Lexan beneath and begin using the jigsaw to cut along the pattern lines. Do not rush; if the blade gets too hot, it will melt the Lexan instead of cutting. Use sharp, fine-tooth jigsaw blades. Go slowly and support the weight of the Lexan and the cut pieces to keep them as level as possible. This prevents the Lexan from pinching the blade, binding, or breaking.
Fitting and Installing the Windshield
After cutting the Lexan, lay your new windshield in the track and check the fitment. Trim any tight spots with your jigsaw or a rasp to ensure the Lexan lays perfectly without hitting the edges. Determine the centerline of the windshield and the roof. Make sure they line up.
Drill the first 3/16” hole at the centerline and insert a cleco. Work one hole at a time, alternating left and right sides. This method keeps the Lexan laying flat without buckles, following the roof’s curvature. The clecos hold everything in place while you drill each new hole.
Once all the holes are drilled and clecos are in place, you can begin riveting. Remove a portion of the protective covering along the rivet hole lines to allow the rivets to pull down the Lexan without the plastic being trapped. Leave the rest of the protective film in place until the car is ready to leave the shop.
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Conclusion
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