How-to: Install rear plexiglass window
#1
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.
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.
Last edited by Taylor; 11-20-2011 at 05:25 PM.
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