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Old 10-29-2011, 01:25 PM   #1
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salzburg , salzburg
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Lexan for corner windows

Hi, I am waiting on the new arrival of my 69 tradewind, whilst i wait i would like to get some supplies ordered so i can start work as soon as she get's here, the trailer is missing the two front corner windows and i would like to replace them with lexan, over here(europe) i have found it in 2'x2' sheets will this be big enough to cover one window? also how hard is it to shape lexan as i take it the corner windows are somewhat curved? also will the whole frame need removing to replace and which seals will i be needing? wow alot of questions, if you can answer any of these it would be great, i have ordered a buckriveting gun so when that arrives i will be teaching myself (and my father in law!) how to buck rivets!, many thanks for any help you can give me,

best wishes,

Richard.
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Old 10-29-2011, 01:37 PM   #2
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Originally Posted by mrgreen View Post
Hi, I am waiting on the new arrival of my 69 tradewind, whilst i wait i would like to get some supplies ordered so i can start work as soon as she get's here, the trailer is missing the two front corner windows and i would like to replace them with lexan, over here(europe) i have found it in 2'x2' sheets will this be big enough to cover one window? also how hard is it to shape lexan as i take it the corner windows are somewhat curved? also will the whole frame need removing to replace and which seals will i be needing? wow alot of questions, if you can answer any of these it would be great, i have ordered a buckriveting gun so when that arrives i will be teaching myself (and my father in law!) how to buck rivets!, many thanks for any help you can give me,

best wishes,

Richard.
The Lexan should be .118 inches thick.

How easy is it to bend?

You can bend that thickness into a tube, if you wish, with your hands.

Take a small piece of it. Set in on a "very good bench".

Then get a sledge hammer.

Ready???

Hit that Lexan piece as hard as you can.

You may dent it, but you won't break it.

The hardest part for you will be taking the wing window sash apart, and then getting it back together again.

The gasket is not available, but you can use Vulkem or Sikoflex sealer in place of it.

The riveting is a piece of cake.

You can also get Lexan with an abrasion coating. With that coating, you can scrub the Lexan with fine steel wool, and "NEVER" scratch it.

You will have a lot of fun with your window project.

Please let us all know how you made out when the window job is finished.

Andy
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Old 10-29-2011, 02:50 PM   #3
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"Lexan" sheet is polycarbonate. Other polycarbonates are also available. The proper way to form them is to dry them at 100 C (low temperature oven) for a hour or so and then drape form them over a proper buck at 200 C. This leaves no residual stress. Polycarbonate does not usually break but is sensitive to solvents and placticizers when under stress.
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Old 10-29-2011, 03:30 PM   #4
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You won't need to heat the Lexan to bend it; the curve on the front windws is gentle enough. The scratch resistant stuff is well worth the price; the time involved in replacement is significant. If you still have the gaskets from the old windows, reuse those.

The replacement windows available today don't exactly fit some of the older Airstreams (corner radii are subtly different); reusing the old frames is less work than piecing in more aluminum to fit the new frames.

The inside sash is quite delicate on our 1971 Tradewind; I've not replaced it yet as it needs some repairs....

Our streetside window broke when we towed the Tin Pickle home for the first time.

- Bart
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Old 10-30-2011, 03:12 AM   #5
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thanks for all the advice anyone know if 2ftx2ft will be big enough for one window?
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