[Chuck]

Installing the Plexi Glass Windows and Light Covers

1. The locations for the screw holes were determined. The spacing for the windows is shown in the photo and is based on a prototype car, although one can see significant variation in the number and placement of the screws on different cars. For the headlight and driving light covers a pattern was made and the spacing determined, then transferred to the body. Pencil marks were placed perpendicular to the edge of the opening.

2. Next quarter inch wide blue vinyl tape was applied around the perimeter of the plexi glass panels. The glass was set in place. The points where the pencil line and the tape intersected was the location for the screws holes. This assured that the screws were placed a consistent and even distance from the edge of the glass.

3. Sixteenth inch holes were drilled to assure the exact location through the glass and into the door or body. After each hole was drilled a nail was inserted to keep it aligned. This was repeated until all the holes were drilled followed by larger holes to accommodate the screws. A 5/32” hole was used on the glass to easily clear the 6/32 stainless screws. A tap was used on the fiberglass to make inserting the screws easier. Since minimal force will be exerted upon these screws, they should be secure simply going into the fiberglass.

4. The screws were placed, being careful to avoid making them too tight. A bit of a gap was left to permit expansion and avoid distorting the plexi glass. When we install the glass for the last time after the car is painted, we may put a tiny dab of silicone on the screws to assure they stay put.

5. We polished our windows with Griot’s Plastic Polish. It was helpful in removing the tiny abrasions that happen when working with this material.