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Old 01-02-2007
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How-to: Install rear plexiglass window

I had pursued a rear glass for the Ranger. A plexiglass unit with optional integrated license plate box. It was not feasible IMO due to the exterior trim. All latemodel Rangers come with rear glass with a built in gasket. After installing the plexiglass, you have a raw plexiglass edge on the outside. I am still looking into options to make the outside more visual appealing. In the meanwhile, I decided to skip the $180 prefab plexiglass units and make my own for the s-10. Here are the results.

The plan was to set the lexan over the opening and trace it. Because of the roll bar, I had to notch that out first. I left the clear protective coating on it so I could use a permanent marker to trace it. The sheet I bought was 30" x 60" which is enough for two pieces.

I used a 4.5" grinder with a thin metal cutting blade to cut it. The grinder cuts easy and has never cracked the plexiglass. I used this because it is what I had on hand. You will need to sand the edges with 80 grit or lighter paper because the lexan will melt while cutting. they turn into hard burrs.

In a Ranger, there are 8 holes in the metal of the truck bor bolting the lexan. After it is cut, I set it back in the opening to mark the holes and drilled them.

You will need to black out enough of the lexan to hide the the glue and headliner. I taped the inside of the lexan, leaving a 2" perimeter open. I sprayed that with black spraypaint and let it dry.

When it was dry, I used windhield sealant (available in a roll at parts stores for $15). Put it around the metal of the truck, stick the lexan on it, and install small bolts to hold it in place. Here is the final install:

I skipped a lot of pics, but hopefully it will be self explanatory with the description.

2004 Ford Ranger Sonic Blue 4dr 4x4 4.0 Manual

Last edited by Taylor; 11-20-2011 at 05:25 PM.
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