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Author Subject: Polycarb windows, weight saving
cjm_harris

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Post #1
Alrite chaps.

Thinking of buying polycarb windows for the front and back (not the rear windscreen at the moment). How much weight do you think I can save over glass in doing this?

I will also be removing all the wiring for the leccy windows, motors etc and cutting away most of the inner door skin.

Trying to weigh up how much weight can be saved to work out if it is worth doing.

Cheers Smile

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Chris
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Posted 25th Jan 2013 at 10:38
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hovis16

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Post #2
I did have a website that sells standard ones that work with winders. Gimme a sec

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Posted 25th Jan 2013 at 10:58
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cjm_harris

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Post #3
hovis16 wrote:
I did have a website that sells standard ones that work with winders. Gimme a sec


Interesting...

I assume its only really worth the weight saving if you get rid of motors/winders etc though?

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Chris
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Posted 25th Jan 2013 at 10:59
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eddy_gti6

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Post #4
Mate i done this in my astor, sure i posted up figures too. Will see what i can find, does make a good bit difference too as i cut my inner door skin out and cut holes in the underside of my doors ect...

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Posted 25th Jan 2013 at 11:04
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hovis16

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Post #5
Plastic4performance

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Posted 25th Jan 2013 at 11:06
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cjm_harris

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Post #6
eddy_gti6 wrote:
Mate i done this in my astor, sure i posted up figures too. Will see what i can find, does make a good bit difference too as i cut my inner door skin out and cut holes in the underside of my doors ect...


Yeah you just went crazy with the holecutter Laugh

Yes it saves weight, but not sure I like the look of random holes Unsure

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Chris
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Posted 25th Jan 2013 at 11:08
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cjm_harris

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Post #7
Chris, can you still get windows made up?

Or is that long gone now?

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Chris
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Posted 25th Jan 2013 at 11:09
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eddy_gti6

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Post #8
I have a set of 3mm rear 1/4s ready to be posted out in 3mm, fronts would need making up tho

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Posted 25th Jan 2013 at 11:11
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cjm_harris

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Post #9
eddy_gti6 wrote:
I have a set of 3mm rear 1/4s ready to be posted out in 3mm, fronts would need making up tho


No rush mate, im skint anyways Laugh

Just wondered if you could still get them made up.

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Chris
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Posted 25th Jan 2013 at 11:18
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eddy_gti6

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Post #10
Cant find my figures off the windows but here is a few things for Weight saving LOL






windows:










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Posted 25th Jan 2013 at 11:19
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owain

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Post #11
If you remove the innards and glass, I reckon 5kg a side or more easy, probably more.

If you don't want sliders in them (or don't mind them looking crap like mine), you can make your own for about £40 Yes

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Posted 25th Jan 2013 at 11:40
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cjm_harris

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Post #12
Owain, can you send me a link where you got your polycarb from? ebay I guess?

And I was planning to make my own and put some of those pop it vents in.

With no exhaust heatshields around gearlinkage area and a supercharger, gets f**king hot in the car, so would need some good cooling.

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Posted 25th Jan 2013 at 11:44
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owain

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Post #13
Bought it off eBay, just make sure you buy Lexan not just standard polycarb; it's easy to tell, it has "Lexan" written all over it. Think I used 4mm for the fronts and 3mm for the sides. It was just a case of measuring up the current glass and waiting for some offcuts to come up that would fit, then marking it out using the old window and running it through a bandsaw. Easiest job ever.

83mm hole cutter (iirc) for the pop-it vents in the back and they make all the difference - people forget that just having front cutouts or sliders doesn't really work, as you need somewhere for the air to flow - you therefore need one or two pop-it vents in each rear to let the air move through the car.

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Posted 25th Jan 2013 at 11:47
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Jake

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Post #14
This reminds me of a thread in the for sale section I need to bump.

http://www.306gti6.com/forum/showthread.php?id=152016

Big grin

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Posted 25th Jan 2013 at 12:19
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Jake

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Post #15
owain wrote:
Bought it off eBay, just make sure you buy Lexan not just standard polycarb; it's easy to tell, it has "Lexan" written all over it. Think I used 4mm for the fronts and 3mm for the sides. It was just a case of measuring up the current glass and waiting for some offcuts to come up that would fit, then marking it out using the old window and running it through a bandsaw. Easiest job ever.

83mm hole cutter (iirc) for the pop-it vents in the back and they make all the difference - people forget that just having front cutouts or sliders doesn't really work, as you need somewhere for the air to flow - you therefore need one or two pop-it vents in each rear to let the air move through the car.


Just read this, that's not true. Lexan is just a different manufacturer of polycarbonate and is not stronger than other types, I found this out last time I ordered polycarbonate from our suppliers as I asked about it. The thickness determines the strength more than anything else.

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Posted 25th Jan 2013 at 18:13
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owain

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Post #16
Well, first I bought standard polycarb and it shattered every time I tried to drill or cut it, and it most definitely shattered when I got so annoyed with another one cracking that I punched through it.

Bought Lexan instead, drilled holes within a couple of mm of the edge, cut them all into shape, not even a single crack.

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Posted 25th Jan 2013 at 19:02
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24seven

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Post #17
^^ First sign of a front-end bump and that thing will crumple like a capri-sun with all those holes in it! Razz

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Posted 25th Jan 2013 at 19:30
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Jake

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Post #18
Polycarbonate shouldn't shatter easily, What was the name of the poly you used?


owain wrote:
Well, first I bought standard polycarb and it shattered every time I tried to drill or cut it, and it most definitely shattered when I got so annoyed with another one cracking that I punched through it.

Bought Lexan instead, drilled holes within a couple of mm of the edge, cut them all into shape, not even a single crack.

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Posted 25th Jan 2013 at 20:54
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owain

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Post #19
No idea, was years ago.

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Posted 26th Jan 2013 at 09:10
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306 Rxs

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Post #20
I firstly used the four side windows in 3mm polycarbonate, and it gave a reduction of almost 6kgs compared to the standard one's.

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Posted 27th Jan 2013 at 12:21
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nick!

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Post #21
It also scratches very easily, so bare that in mind if you keep the standard winding mechanism rather than go fixed.

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Posted 27th Jan 2013 at 18:05
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306 Rxs

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Post #22
Don't you have the chance to buy the non scratching option?
Here it's a bit more expensive, but it's possible to choose it.

I didn't need that because my windows are already fixed.

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Posted 27th Jan 2013 at 19:31
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Jake

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Post #23
Yes there is a scratch resistant version which is what I will use when it comes to making my front windows as when the sliders open/close they get scratched aswell as when fitting, but i've never seen polycarbonate windows on winders and see no point in doing that. With regards to weight I have no idea, would have weighed mine at the weekend but I've no decent scales! I'm sure Eddy posted weights up the for window for sale thread.

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Posted 28th Jan 2013 at 19:35
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eliotrw

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Post #24
How much lighter is the poly window versus the glass then?
Personally I think the very last thing i would do for weight saving is the poly windows as it just seems like a lot of ball ache for little gain.
Obviously a track car is a track car though

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Posted 28th Jan 2013 at 19:49
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306 Rxs

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Post #25
Almost 6kgs for the 4 side windows, using 3mm poly's!!

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Posted 29th Jan 2013 at 06:29
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