Perspex windows DIY...

Post Sat Oct 04, 2008 8:28 pm

I might be interested in some for my touring depending how much weight they save over glass ??

Post Sat Oct 04, 2008 11:09 pm

We'll weigh the first set that we cut and i'll report back - I believe that the door glass on a touring adds up to about 13-14kg, and I'd hope that the polycarbonate set weighs no more 6kg, maybe 5 (~1 square metre of 4mm thickness, density 1200kg/m3). With the boot windows as well, you're looking at going from about 20kg all in down to maybe 7.5-8kg.

Post Sun Oct 05, 2008 6:16 pm

Thanks for the info Mike, if i get these i was thinking of bonding the rears and bining the winder mechs' so may be another 2-3kgs to be saved there ?

Post Sun Oct 05, 2008 10:22 pm

That's exactly what we're doing Andy - the windows mechs are quite heavy! We've also done the same to the fronts, but that's due to our car being track-focused. Rear mech assembly weighs about 2kg each side, fronts are almost 3kg each.

Post Tue Oct 07, 2008 7:43 pm

Any news?

Post Tue Oct 07, 2008 7:45 pm

Sorry, i'm out ref my sig pic

Post Tue Oct 07, 2008 9:31 pm

Mike

I am just down the road from you and would be interested in replacing my windows (4 door 325). I can bring the car around if you want (might help some more on here if you need templates).

Post Wed Oct 08, 2008 7:24 am

oldroydsr4 wrote:Any news?

We're just waiting for a free evening to pop up so that we can complete the digitisation of the touring glass scans - Mark and I both work at the same place, and it's been ridiculously busy the last few weeks. We're still aiming for (at the very least) a trial set to be cut within the next two weeks - then once we've measured and test-fitted, we can cut a set for you oldroydsr4 and anyone else who wants touring glass. Once we've done the trial set, we can confirm final pricing and take "orders" from anyone who wants a set, and cutting and delivery can take place immediately. Anyone apart from oldroyds4 tempted to have a set?

moggy - the main door windows on a saloon are the same as on a touring (we think), the only one we'd need to measure is the rear most pair of windows that join up with the C-pillar. Only problem is, they ideally need to be out of the car...whereabouts are you? Your offer of help is much appreciated

Post Wed Oct 08, 2008 8:13 am

Very intrsted,

I have also asked someone else for a price including slider on the drivers window, So I will compareing and getting the best quality one.

Post Sat Oct 11, 2008 11:45 am

mike_sayer wrote: moggy - the main door windows on a saloon are the same as on a touring (we think), the only one we'd need to measure is the rear most pair of windows that join up with the C-pillar. Only problem is, they ideally need to be out of the car...whereabouts are you? Your offer of help is much appreciated

I'm in Timperley

Happy to come across

Post Sat Oct 11, 2008 5:28 pm

Have we got any pics yet?

Post Sun Oct 12, 2008 8:37 pm

oldroydsr4 wrote:Have we got any pics yet?

Indeed we do

. Just got back from a weekend away and Mark has taken care of the digitisation - here's a screenshot. Test cutting of the first set is still planned for next weekend - so we'll have pictures of the results and final price details then.

Post Sun Oct 12, 2008 8:59 pm

Awesome can't wait

Post Mon Oct 13, 2008 2:29 pm

Will you be doing the very back side windows as they are the biggest. I know they are bonded but still got to be done. ????

Post Mon Oct 13, 2008 5:42 pm

zaust wrote:Will you be doing the very back side windows as they are the biggest. I know they are bonded but still got to be done. ????

Yes, we definitely will be doing this for our project car so these will be available too - just haven't had the chance to digitise them yet. Hoping to do these this week so that we can cut a trial pair with all the door windows next weekend

Post Sun Oct 19, 2008 10:30 am

Are the test set fitted yet?

Post Mon Oct 20, 2008 6:37 pm

Hello guys,

I'm the Mark undertaking the Touring project with 'Mike_Sayer'

Good to see you’re interested in the windows. I machined a couple of trial windows this weekend, just from 4mm ply - to check that converting between various necessary Software packages hadn't affected the profile, and it hadn't.

The windows, all be it wooden... fit really well, and I'm now confident in the procedure to take orders to make poly carb!

As Mike mentioned, were trying to get hold of the coupe, and four door glass to offer these as well, and with a little time could do other models to - (the only limiting factor being the glass curvature, if the glass has barrel, then they would need to be sag formed)

So please contact either myself or Mike if you’re interested, and hopefully we can save you some money!

Cheers guys

Post Mon Oct 20, 2008 6:38 pm

Price and pic's first fella.

Post Thu Oct 23, 2008 9:58 pm

I agree - and I've already said I can pop down with my 4 door.

Post Fri Oct 24, 2008 1:07 pm

Still 100% on these, let me know when you need payment

Post Fri Oct 24, 2008 1:16 pm

Apologies for the slow progress here guys. Mark and I heading back to the workshop on Thursday next week. On the Friday we intend to purchase the polycarbonate and hopefully get at least two sets cuts - one for us and one for oldroydsr4. We'll post pics of the windows up as soon as they're done, along with final pricing and my mobile number. Then, if people would like a set, they can phone me over the weekend and we can cut to order - including quarter lights if required.

Moggy - lets look at your 4 door after next weekend when we've done the touring glass cuts. Is that OK with you?

Again, sorry for the delay - Mark and I are both very busy with work and finding time to get down to the workshop has been tough. We'll be back with more next week!

Post Fri Oct 24, 2008 4:51 pm

No problem

Post Sun Oct 26, 2008 9:00 pm

mike_sayer wrote:
Moggy - lets look at your 4 door after next weekend when we've done the touring glass cuts. Is that OK with you?

No problemo

Post Sun Nov 02, 2008 6:29 pm

Progress! We now have the CAD finished, the trial set cut in plywood to check dimensional tolerance, and we've cut the first set of door glass on the CNC machine - which are reserved for you oldroydsr4. The material that we've used is 4mm thick, UV-protected polycarbonate - almost impossible to smash, resistant to sunlight (so won't go yellow or brittle) and scratches (and any scratches are easy to buff out), and a lot lighter than glass. We'll weigh the set of door windows tonight, but I reckon they're less than half the weight of the glass.

Price for a set of door windows (two front, two large rears and the two small trapezoidal shapes at the rear of the rear doors) will be £130 plus delivery (~£10). We haven't cut a pair of boot windows (quarter-lights) yet, but if you'd like these as well then total cost will be £180 plus delivery.

If you'd like a set, please PM me. Now we have the CAD files all set up, cutting should be able to be done within a week of you ordering.

Oldroydsr4 - please get in touch if you'd like "your" set, and we'll get them posted!

Here are some pics of the cutting and the finished items. I've also got a video of the CNC machine in action which i'll have a link for later - YouTube is just "processing" it...

Cheers,

Mike

EDIT: Here's the video of the machine in action...

Post Mon Nov 03, 2008 3:02 pm

Can you do slider's ????

(front only)

Post Mon Nov 03, 2008 3:18 pm

We could probably make the cut out and the sliding window, but not the two little brackets that hold the slider on to the main window. If there's somewhere that sells them, we could make modifications to allow them to be fitted

Post Thu Nov 20, 2008 9:11 pm

woooow this is awsome !

i would love to have a machine like that !

wouldnt mind a set of 2 door window too

Post Tue Nov 25, 2008 4:21 pm

Those look great, lets get some for two doors!

Post Tue Nov 25, 2008 4:27 pm

Windows for 2-doors and 4-doors are currently in progress...all being well the CAD models for both will be done by the end of this coming weekend. Does anyone have a spare rear side window from a coupe that they could lend us (needs to be out of the car and free of seals)? We have access to the fronts, and to the rears for the 4-door - just the coupe rear side that we're missing. As soon as we have that, we'll be able to confirm prices for coupe sets and get the machine fired up again. In the meantime, anyone who wants a set for a touring should get in touch - we can have them cut and delivered within a week of ordering!

Cheers,
Mike

Post Wed Dec 03, 2008 7:13 pm

interested in a 4door set dude...let me know once ya have them sorted...

Post Thu Dec 04, 2008 12:14 pm

4-door glass CAD model will be ready tonight - so we should be ready to cut very soon once the dimensions have been checked. I've sent you a PM, Lee.

On the coupe-front, we now have a front window and i'm collecting a rear window next Monday. So next week we should be able to get those scanned, and we'll be ready to start offering polycarbonate windows for coupes.

Cheers,
Mike

Post Fri Dec 05, 2008 10:42 am

Quick update - couple of screenshots of the now complete glass models for touring and 4-door respectively. Coupe model will be ready next week

Touring

4-door

Post Fri Dec 05, 2008 11:39 am

Suggestion's for mounting please. Or will they fit in the o/e runner's ?

Post Fri Dec 05, 2008 12:00 pm

They're exactly the same size as the original glass, so should fit in the runners - but we haven't tested that. On our car, we're going to bond them in with tigerseal with the original seals, so that they're nice and watertight and also look standard around the edge of the window.

Oldroyds4r already has a set - Dave, how do you plan on fitting yours?

Post Fri Dec 05, 2008 9:41 pm

Reason i'm asking is because the o/e galss is concaved, and i'm wondering if it is fitted to the runners will it keep poping out at the top if used as normal.