Desperate for ideas on windshield replacement

dodge guy wrote:
Sorry, i said glass. I meant plastic front window.

Never thought it would be plastic from factory!

Here is my thoughts on this..

Plexi or Lexan CAN be "bent" with the proper amount of heat. I have done this in the past with SMALL pieces but never with this size.

A few internet searches basically reveals some ways that it can be done DIY.

Some have mentioned a hair dryer, propane torch, heat gun (typically used to strip paint or shrink heat shrink tubing), heating pads and so on.

In the past I simply used a home oven (like I said small parts) set to 350 or so. Basically made a form for the plexi to sit on and placed in the oven. Then wait for plexi to get soft and mold into the form. Take out and let cool.

Large sheets of plexi and Lexan are not cheap so you don't want to make any mistakes (basically need to nail it the first try).

I would recommend making a form which fits into the window opening. Basically place a piece of plywood behind the opening then with strips of wood you build up the form to meet the curves of the opening.

Take the form out of the opening and now you have an easy means to work with the plexi or Lexan.

If you have the budget I would say Lexan would be the better choice since it won't shatter like plexi does if you don't get it hot enough.

You need to heat it slowly otherwise you can blister it, one place mentioned the idea of heating pads and blankets and wait several hrs for the plastic to soften (this may be the best solution since direct heat can over heat the plastic to fast and blister or even burn it).

You could even make a make shift "oven", just need to make a box big enough to fit the form and insulate it well then add some heat source like heat lamps or a couple of electric heaters. Add in a thermometer to monitor the temps.

You only need enough heat to simply soften the plastic, once soft it will easily conform to your form.

I would cut the plastic a bit larger than your form leaving extra will allow for any mistakes like not lining up the plastic perfectly with the form.

Thinner plastic will form easier but too thin will allow more flex than you want or need so you are going to have to balance that carefully. I'm thinking 1/8" might be too thin and may want to bend and or pop out while towing. 1/4" most likely would be the better choice since it should stay rigid enough to withstand highway speeds.

I would think that making a DIY double panel like OEM would be a bit of a stretch so I would think you are going to have to settle on single pane.

As far as mounting the plexi, you can find rubber gasket material which should be similar to what the OEM window used, just not sure as to how you seal up the two ends when they meet together so they stay sealed. You could use the old school auto glazing sealant which was used on vehicles in the 1980s or older, typically called bedding compound if I remember correctly. This stuff makes a mess but boy does it make a good seal..