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Old 05-26-2019, 12:52 PM   #15
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When you are saying, you like to score the straight cuts, do you mean no saw cutting? Just scoring and snapping/breaking the straight lines? Good job.
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Old 05-26-2019, 02:31 PM   #16
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When you are saying, you like to score the straight cuts, do you mean no saw cutting? Just scoring and snapping/breaking the straight lines? Good job.

Yes, score (3-4 times with a sharp blade) and snap by placing a piece of wood the length of the cut under one side. The risk with cutting plexi glass is always breaking the corners. If you decide to rather use a jig saw on a straight cut, do not attempt to cut all the way to the end, but rather stop a few inches short, then support everything and finish the last few inches from the uncut end.
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Old 05-27-2019, 11:41 AM   #17
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. Was the replacement spline difficult to find?

..

---Daniel
------------
2017 FC 25 RTB
2017 F150 Lariat

I stand corrected on the spline, its readily available in 13/64, but only in long rolls. I found a section of new spline in my shop, so I looked online and found it at various locations:
https://www.midlandhardware.com/5269...iABEgKX3fD_BwE
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Old 05-27-2019, 12:27 PM   #18
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I just recently replaced some spline on our rock guards. Used a 25' pack of 0.225" black spline from Amazon for $5.37. It seemed to work fine even though it is about 0.022" larger than 13/64.
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Old 05-28-2019, 04:40 PM   #19
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Wish I hand this info about 15 years ago when I discovered that my daughter could hit a soft ball a lot farther than I thought! I ordered the replacement corner panel from AS at what I considered to be an outrageous cost. It came in a new, aluminum frame, with hinges that, had I used them, would have had to be attached to the frame and the trailer--but the plexiglass and frame were a little taller than the original--the width was OK--so I had to have the local glass company cut/trim the plexiglass to fit my original frame. Even if it the plexiglass was the correct size, I would have used the original frame to avoid messing with the hinges. The plexiglass must have been thicker and bent with heat, though--it did not loose its shape when removed from the frame..
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Old 05-28-2019, 05:17 PM   #20
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Why not use lexan instead of plexiglass when repairing rock guards? Lexan much more resistant to damage than plexiglass, not expensive only couple $ more & a little easier to fab. as doesn't crack as pg does. Use jig saw slo speed.
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Old 05-28-2019, 06:52 PM   #21
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Thank you for the excellent tutorial. I am also wondering about lexan in lieu of plexiglass. Jim
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Old 05-28-2019, 07:04 PM   #22
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Why not use lexan instead of plexiglass when repairing rock guards? Lexan much more resistant to damage than plexiglass, not expensive only couple $ more & a little easier to fab. as doesn't crack as pg does. Use jig saw slo speed.

Source it, fab it and post your experience and results.
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Old 05-28-2019, 07:57 PM   #23
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I used Lexan. Cut it with a plywood blade in a skill saw.
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Old 05-28-2019, 11:03 PM   #24
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Twinkies, were you able to find the smoked or bronze color lexan?
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Old 05-29-2019, 09:53 AM   #25
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Not sure if this is what you are looking for. It is called "Dark Tint"
I bought it on ebay from a vendor named "popdisplays" 38736
They will cut it to your specs at no charge.
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Old 05-31-2019, 04:51 PM   #26
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Peter, thank you for taking to time to photo document and share. This is outstanding!

Janet are listening , can this be made perm?

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Yes - I am listening but was camping....

The thread is stuck - nice write up Peter!

I also made a pdf of the pertinent bits so you can print it and take it out to your project rather than having to bungee your laptop to the front of your airstream while you work

replace plexi-rock guards.pdf
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Old 06-02-2019, 12:59 PM   #27
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polycarbonate versus plexiglass

Those questioning the use of the acrylic plexiglass versus polycarbonate Lexan are right to favor Lexan for rock guard use in my opinion. Polycarbonate is much stronger but also more flexible which minimizes risk of cracking from rock impact. Polycarbonate is more expensive but worth the cost. Does the acrylic sheet have a protective peel off warning that suggests avoiding exposure to direct sunlight? Hmm, why would you want a rock guard that should be kept out of direct sun?
Of course all are free to use whatever they want to use just as we are all allowed to express opinion.
Best,
Jim
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Old 06-02-2019, 05:09 PM   #28
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Those questioning the use of the acrylic plexiglass versus polycarbonate Lexan are right to favor Lexan for rock guard use in my opinion. Polycarbonate is much stronger but also more flexible which minimizes risk of cracking from rock impact. Polycarbonate is more expensive but worth the cost. Does the acrylic sheet have a protective peel off warning that suggests avoiding exposure to direct sunlight? Hmm, why would you want a rock guard that should be kept out of direct sun?
Of course all are free to use whatever they want to use just as we are all allowed to express opinion.
Best,
Jim

Perhaps you should start a new thread called polycarbonate versus plexiglass.
I named this thread :Replacing your plexi glass Rock Guards / Stone Guards with the intention to provide, for free to the Airstream community, step by step instructions incl the source and cost of materials.
The problem with ordering a new set from Airstream, is not only the staggering cost, but the risk of breaking your panoramic windows, since the new brackets never line up and the new ones need to be drilled and riveted dangerously close to the glass.

One could probably follow the same instructions using Lexan, but the material cost would be at least double.
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