Making and installing lexan windows.

This is a technique that I use on bodies that do not come with vacuum formed windows. Here are some of the tools and supplies that I use.

-X-Acto Knife with new blade

-Sharpie

-Masking Tape

-Pacer formula 560 canopy glue

-Paint brush, flat black bottle paint

-Scissors (not shown)




Step 1, Tracing windows

The first step I take is tracing the windows. I use masking tape to help hold the lexan in place. Take a sharpie and trace out the window openings.




Step 2, Cutting out windows and trim

Cut out the patterns you traced. I like to cut them a little bit larger (outside the lines) so that I can put the window in place on the body and  continue to trace and trim until the fit is right. Once I like the shape and fit I place the window upside down on masking tape that I have secured to a piece of card board. Since the lexan provided has protective film on both sides it acts as a mask  that comes in handy for doing the black trim. Take an X-Acto knife with a new blade and trim around the edge.




Step 3, Remove mask


Once you've trimmed it out, simply remove the mask where you'll be applying paint.



Step 4, Paint window trim


I use an airbrush with black lacquer paint. I like using an airbrush because you can get good coverage with thin layers. Rattle cans will also work. When I do use rattle cans, I like to warm the can up before spraying by taking an old coffee container and filling it up with hot water then placing the can in the water for about 10 minutes. This helps thin out the paint. When using rattle cans, don't coat the windows with one swipe. Hold the can about 10" away from the surface that you're painting and give it a couple light coats. Let it sit a few minutes then  repeat this step until you have good coverage.



Step 5, Remove protective film


Remove the protective film on top but leave the windows on the masking tape and set it aside for now.



Step 6, Paint the window openings


By painting the window openings black, it'll give your finished product a more detailed look. I like to mask the outside of the body then brush on some flat black.



Step 7, Get your glue on


I apologize for not getting a picture of when I applied the glue. I'll add that the next time  do windows. Take a tooth pick and apply a bead of glue around the window opening. Put the window in place then tape it down.



Step 8, Clean up


Let the glue set up for a couple hours before removing the masking tape. Don't worry if you get too much glue on the windows or body. This glue cleans up nicely with a wet paper towel and a wet tooth pick. The picture shows dried up glue on the inside of the window. By using a wet tooth pick and gently rubbing the dried up glue, It'll turn back into a liquid paste which makes it easier to clean up. A cotton swap also works well for clean up. 



Step 9, Finished


It does take practice and patience however I feel the finished look is worth it.



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