For those of you that need to know, patterns for glass are made the same size as the NEW window holes. I did my lexan windows and they fit perfectly.
Edit: I put a piece of cardboard up to the backside of the opening and trace the hole on it. Once I have a good even fit inide the window hole I transfer the pattern to gator board for a permanent pattern then to the lexan itself.
I have the front glass installed and it fits perfectly, if anything I might make the next set 1/16" larger than the hole.
Last edited by FITNESSFORYOUTOO on Mon Nov 24, 2008 7:34 pm, edited 1 time in total.
Fitness,
Just got done with my chopped glass. You are right about the 1/16 bigger on the quarters. I cut some cardboard for the doors and installed them just as windows with the trim in for a perfect fit. The rear was a bitch! The angle changes so if you cut it to fit the opening, it will be too small. So I cut a piece of luan underlayment and installed it as a window first to get the correct fit. I used 1/4" thick Lexan and a heat lamp to relax it. The lower corners really sucked! I am not sure if I should have used 1/8" thick but I was affraid it would leak. It would have been much easier.
Kubel Nick wrote:You can chop safety glass, or get new ones made. Easy and cheap to get new flat glass made. On curved glass, the windshield can be cut with different methods (sand blast, tile saw, grinder, etc). It may take a few windshields before you get a good one done. If you take it to a shop for them to chop noby will guarantee they won't crack a few windshields neither.
I usually cut my blade using a tile saw.. Really effective to cut using this one.
