Window project

Well, after busting out my rear cargo window on this trail (https://www.youtube.com/watch?v=caN6YkIBxg8) and spending the rest of the day accessing my tools through the hole in the side that used to be a window, I realized how handy it was to not have to pull the tire carrier open and the tailgate to access so I decided to build a hinged window.

I started by cutting down the old gasket so it still held a seal around the lip of the window opening.

I went to Home Depot and got a piano hinge, and a bunch of nuts and screws. I cut a paper template and took that to a plastics supplier in town and purchased a sheet of smoked plexiglass ($40). I cut it to size and then then used a dremel with sanding inserts and a polishing stone to tweak the fit.

When it was all in place, I realized the biggest flaw in my plan. The window opening is concave, but the plexiglass is flat. I was able to solve that by sandwiching the corners with aluminum sheets, drilling a hole in the window frame and the window and using clevis pins and hitch pins to hold them in place. I do have a "tool box lock" that I haven't installed, but will be soon.

I drove it last night in the pouring rain. It isn't 100% water tight, but very little intruded. It's a little noisier than the fixed window and doesn't seal tight on the bottom. However, for a primary trail rig, it will work great. If, eventually it breaks or I determine it isn't as good a plan as I thought I'll drop $25 at the pull a part and get a replacement glass and gasket.

How flexible is the plexiglass? I just did mine with lexan, it flexes well. Think it'd be really tough to break it. Nice idea tho!

NICE! That is pretty slick.
You can get some thicker Lexan and heat it to form a curve also.

The plexi is pretty rigid. I think it will last fine, but not sure. I cracked at least 3 corners on the project while drilling, which lead to the need for the aluminum sandwiches in the outer corners. It's not super pretty up close due to mis-cuts, using a Skilsaw, and having to sand down the edges with a Dremel, but I'm cool with it.

Time will tell. If nothing else, I was able to engineer a useful solution to a problem and have a pretty close template for a second attempt if the need arises.

Trippled - did you hinge yours for access, or did you just do a solid replacement? If you hinged it, I'd like to see a photo of your design.

I just did a replacement. I put my filler door in the window which is why I did it and needed doing the other just because. If it does break look into the lexan tho. Really flexible and drilled/cut well. I used the cheap glass cutter tool with a long ruler. You basically score it then break the side off. Took some work but good cuts.

cool idea. Not a bad weight-loss upgrade either.