Author Topic: How to - making calibra polycarb windows:  (Read 6296 times)

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Offline tommygards

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How to - making calibra polycarb windows:
« on: August 21, 2011, 14:12:00 PM »
If somebody could put this in the how to section, i know some people were interested in doing this.

Making polycarb windows is actually quite easy, not only is it lighter than glass,  but it also allows you to remove the heavy window regulator and cut the middle out the door which is not structural and also cut out the door bars if you want.

I used 5mm shatter proof polycarb, its the same thickness as the glass and fits well into the door recess. I got 2 sheets of 2' x 3' which is a good size to make the windows out of.

Removed the windows and used it as a template to cut out the of the polycarb:



cut out using a jigsaw, didnt shatter at all when using it or drilling it so no concerns about it shattering or cracking.



then taped it to the glass window and ran over it in strips with a heat gun which helped shape it.  POLYCARB DOES HAVE A PREFERRED DIRECTION OF BENDING. So it will mould 1 way a lot easier than the other, you will only find out which is the preferred once you have tried moulding it, if it doesnt work then turn it round and use it as the other window.



after moulding:





cut the centre out the door, not a requirement but i wanted to cut more weight out the car and made it easier to get the window regulator out.



then i cut 2 strips of metal out of 2mm sheet. strips were 1.25 inches wide and 22 inches long.  I then bent 1 of these to the shape of the window and mounted through 2 pre-existing holes in the door using M6 bolts.

I then used the other strip as a brace to help maintain the bend in the polycarb, it also doubles well as a handle.



and the finished window:









tada!! hope it helps people.

Offline Phil.

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Re: How to - making calibra polycarb windows:
« Reply #1 on: August 21, 2011, 14:50:21 PM »
Nice one!

Myself and 2 mates are looking at building a track car and this has been very helpful :)
Audi S4 2.7 Twin Turbo Avant, RS4 Turbo's + Intake, 2.5'' Turbo's Back Exhaust, Fully Rebuilt Cylinder Heads, RS4 Fuel Pump + Injectors, Coilovers, RS6 Seats, 18'' B6 Alloys, RS4 360mm Fronts, RS4 321mm vented rears, RS4 Spoiler, much more!

barrachops

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Re: How to - making calibra polycarb windows:
« Reply #2 on: August 21, 2011, 18:04:16 PM »
Nice work, where did you buy the shatter proof polycarb from? I need longer sheets though as I will be making the window the full length of the door to include and the quater light glass

Offline tommygards

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Re: How to - making calibra polycarb windows:
« Reply #3 on: August 21, 2011, 18:05:23 PM »
I got the polycarb from work, so not sure where to buy it.  sorry mate.

DrZux

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Re: How to - making calibra polycarb windows:
« Reply #4 on: August 21, 2011, 18:09:26 PM »
I got the polycarb from work, so not sure where to buy it.  sorry mate.
LOl the answer should be, I'll get you some mate for such and such a price :P

barrachops

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Re: How to - making calibra polycarb windows:
« Reply #5 on: August 21, 2011, 18:15:49 PM »
LOl the answer should be, I'll get you some mate for such and such a price :P

:D Looks like sticking to the original plan then, I found a guy a while back that can make them if I supply him with a template for the whole door glass (to include the quarter glass and width of bar) and rear quarters and will fit window sliders for

Offline GreddRob

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Re: How to - making calibra polycarb windows:
« Reply #6 on: August 21, 2011, 20:49:15 PM »
Nice work dude
M&R

Offline tommygards

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Re: How to - making calibra polycarb windows:
« Reply #7 on: August 22, 2011, 20:30:40 PM »
can somebody please move this to the calibra guides section? :)

Offline ALZ1307

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Re: How to - making calibra polycarb windows:
« Reply #8 on: August 22, 2011, 20:33:59 PM »
Done.
Lewis Hamilton said that winning his first race felt better than having sex. Kimi's reply to that was, Maybe he never had sex.

Offline tiff_lee

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Re: How to - making calibra polycarb windows:
« Reply #9 on: August 26, 2011, 17:35:28 PM »
Good tip on the moulding, I fitted some polycarb windows in my R5 GT Turbo from plastics4performance and they are a complete pain to do up (not moulded).