Overview:
So you've either decided to take your DSM's weight loss to the next step, or more likely you are ready to turn your DSM into a track only car. One easy way to shed some weight and make your DSM ready to take on the track is by ditching the glass and making your own Lexan Windows. This job can easily be done with a few simple tools and a sheet of Lexan from Home Depot. It is generally done along with gutting the doors as seen here: http://www.dsmtuners.com/forums/articles-exterior-interior/254282-how-gut-your-1g-doors-weight-loss.html. Together with gutting the doors and making Lexan side windows I dropped 40 pounds per side so a total of 80 pounds.
Tools Recommended:
• Lexan (I used a 72"x36" sheet that was .093" thick and cost $99 from Home Depot)
• Drill and bit
• Riveter and rivets
• Cutter (I used an angle grinder with a cutoff wheel)
Proper Safety Precautions:
Be sure to wear safety glasses when cutting or drilling and work in a well ventilated area.
Why Lexan?
Lexan is a special type of polycarbonate sheet that is lightweight, shatter resistant, 250 times stronger than glass, and has a 10-year limited warranty against yellowing. They market it as being virtually unbreakable. I used .093" Lexan, which is a little thinner then the stock glass. It feels a little bit flimsy once installed but I drove it around and didn't experience any negative effects. With the goal of weight loss it is a good choice. The stock glass is 1/8", comparable to the .118" thickness Lexan Sheets. The .118" sheets would have to be special ordered from Home Depot and are more expensive. I would definitely use the thicker stuff for the windshield and larger rear hatch.
Steps
The first thing you need to do is remove the glass out of your door. With the panel removed and the window rolled down about 90% of the way there is an access hole that will allow you to remove the two 10 mm bolts that hold it to the lift assembly. Then the window lifts up and out at an angle.
Once the window is out you will need to trace it onto the sheet of Lexan. Since in this case we will be riveting the Lexan into the door, it can be about an inch shorter then the original glass window. I used clips to hold the window to the Lexan while forming it to the contour of the glass and had an assistant (my wife) trace it out for me.
Once it's traced out it is time to move to the garage to cut out the Lexan window. I used an angle grinder with a cutoff wheel because that is what I had. A jigsaw would probably work even better. Whatever you use, just follow the line.
Since I was using a cutoff wheel it left some melted residue along the edges which I quickly trimmed off with a knife.
At this point you can test fit the Lexan window into the door. Make sure that he Lexan is pressed all the way up into the slot and is under the rubber seal.
With the Lexan pushed all the way up, go ahead and drill your holes for the rivets. I used 1/8" rivets so a 1/8" drill bit. Drill your holes evenly spaced all the way across the bottom.
Once the holes are drilled pull the Lexan window back out and remove the plastic protective coating off of each side and reinstall the window in the door.
Now we just install the rivets and we are done. I used a cheap handheld riveter from Home Depot and it worked great and was easy to use.
Now just wipe it down and you are done!
If you found this tech article helpful please rate it as such. If you have any questions, suggestions, or helpful tips, please PM me and I will add or clarify to make it better.
I hope this helps!
Nathan
So you've either decided to take your DSM's weight loss to the next step, or more likely you are ready to turn your DSM into a track only car. One easy way to shed some weight and make your DSM ready to take on the track is by ditching the glass and making your own Lexan Windows. This job can easily be done with a few simple tools and a sheet of Lexan from Home Depot. It is generally done along with gutting the doors as seen here: http://www.dsmtuners.com/forums/articles-exterior-interior/254282-how-gut-your-1g-doors-weight-loss.html. Together with gutting the doors and making Lexan side windows I dropped 40 pounds per side so a total of 80 pounds.
Tools Recommended:
• Lexan (I used a 72"x36" sheet that was .093" thick and cost $99 from Home Depot)
• Drill and bit
• Riveter and rivets
• Cutter (I used an angle grinder with a cutoff wheel)
You must be logged in to view this image or video.
You must be logged in to view this image or video.
Proper Safety Precautions:
Be sure to wear safety glasses when cutting or drilling and work in a well ventilated area.
Why Lexan?
Lexan is a special type of polycarbonate sheet that is lightweight, shatter resistant, 250 times stronger than glass, and has a 10-year limited warranty against yellowing. They market it as being virtually unbreakable. I used .093" Lexan, which is a little thinner then the stock glass. It feels a little bit flimsy once installed but I drove it around and didn't experience any negative effects. With the goal of weight loss it is a good choice. The stock glass is 1/8", comparable to the .118" thickness Lexan Sheets. The .118" sheets would have to be special ordered from Home Depot and are more expensive. I would definitely use the thicker stuff for the windshield and larger rear hatch.
Steps
The first thing you need to do is remove the glass out of your door. With the panel removed and the window rolled down about 90% of the way there is an access hole that will allow you to remove the two 10 mm bolts that hold it to the lift assembly. Then the window lifts up and out at an angle.
Once the window is out you will need to trace it onto the sheet of Lexan. Since in this case we will be riveting the Lexan into the door, it can be about an inch shorter then the original glass window. I used clips to hold the window to the Lexan while forming it to the contour of the glass and had an assistant (my wife) trace it out for me.
You must be logged in to view this image or video.
You must be logged in to view this image or video.
Once it's traced out it is time to move to the garage to cut out the Lexan window. I used an angle grinder with a cutoff wheel because that is what I had. A jigsaw would probably work even better. Whatever you use, just follow the line.
Since I was using a cutoff wheel it left some melted residue along the edges which I quickly trimmed off with a knife.
You must be logged in to view this image or video.
You must be logged in to view this image or video.
At this point you can test fit the Lexan window into the door. Make sure that he Lexan is pressed all the way up into the slot and is under the rubber seal.
You must be logged in to view this image or video.
You must be logged in to view this image or video.
With the Lexan pushed all the way up, go ahead and drill your holes for the rivets. I used 1/8" rivets so a 1/8" drill bit. Drill your holes evenly spaced all the way across the bottom.
You must be logged in to view this image or video.
You must be logged in to view this image or video.
Once the holes are drilled pull the Lexan window back out and remove the plastic protective coating off of each side and reinstall the window in the door.
You must be logged in to view this image or video.
Now we just install the rivets and we are done. I used a cheap handheld riveter from Home Depot and it worked great and was easy to use.
You must be logged in to view this image or video.
Now just wipe it down and you are done!
You must be logged in to view this image or video.
If you found this tech article helpful please rate it as such. If you have any questions, suggestions, or helpful tips, please PM me and I will add or clarify to make it better.
I hope this helps!
Nathan
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