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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?

Bob
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,
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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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Old 06-03-2019, 09:28 AM   #29
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Instructions valid regardless of glazing material

Peter,
Of course you are correct, your very detailed instructions are quite helpful regardless of whether one selects plexiglass or polycarbonate. Thank you!
Jim
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Old 06-04-2019, 06:29 AM   #30
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Peter, thanks for the write up....pretty straight forward. One question....when you are using the old corner segment plexi for a pattern, does it want to flatten out easily, or is there a trick to accurately marking out on the new sheet?
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Old 06-04-2019, 01:16 PM   #31
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Peter, thanks for the write up....pretty straight forward. One question....when you are using the old corner segment plexi for a pattern, does it want to flatten out easily, or is there a trick to accurately marking out on the new sheet?

I found if they are very old, they will break when you try to flatten them. But the broken pieces are still sufficient to use as a good template. If you are concerned about accuracy, trace the removed curve panel on a piece of thick paper first.
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Old 06-04-2019, 01:58 PM   #32
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I found if they are very old, they will break when you try to flatten them. But the broken pieces are still sufficient to use as a good template. If you are concerned about accuracy, trace the removed curve panel on a piece of thick paper first.
Gotcha, thanks. Excellent write up.
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Old 06-04-2019, 03:09 PM   #33
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Replacing your plexi glass Rock Guards / Stone Guards

An easy tip to facilitate tracing a curved object.

Put the paper on the convex (outside of the curve) side if the material. Cut a few square ‘windows’ in the paper so you can put blue painters tape over the windows to hold the paper in place as you use a pencil to accurately mark the edge of the old one.

Then carefully peel the paper off, trim along the line carefully, and stick it down on the new material. Mark and cut just outside the line to make the new sheet.

Trick taught to me by a guy named Andy, who used this method to seamlessly cove vinyl floor covering up the walls. He claimed to have invented the technique, and he and his tools were old enough for that to be true.

RIP Andy, you were a true craftsman! The job he did for us years ago looked like the material had grown there.
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Old 08-06-2020, 11:45 AM   #34
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Excellent how to do it yourself conversation. In the process of getting the old center section apart to measure for a new panel I broke two of the cast elbows internal to the frame that the rivets insert into holding everything together. The casting failed at the rivet hole.

Any idea where these are available? I've made some local phone calls but no luck.

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Old 03-09-2021, 10:08 AM   #35
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Thank You

thank you so much! this is just what I was looking for -
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Old 04-12-2021, 05:18 PM   #36
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Reviving this, as replacement is on my spring list. I called a shop which specializes in plastic sheet and was told he would not recommend polycarbonate for a curved application. He said it will look good for some time, then will start crazing and cracking on the radius.
For those who used polycarbonate, how has it performed over time? How long? Any other commentary from both camps?
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Old 04-13-2021, 06:34 AM   #37
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I've got the same plans and I'm leaning toward the poly. My 35 year old plexiglass has all the stress cracks and spider lines I think you are talking about. Does the dealer have a time frame before the cracks show up?
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Old 04-13-2021, 08:09 AM   #38
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polycarbonate rock guard

The comment about poly not enjoying being curved might be right although my poly guard has a curved corrugated surface, overall it is flat. These curves were probably formed with the plate warmed to be flexible. Installed in 2017, I have seen no deterioration in this product.
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Old 04-13-2021, 08:15 AM   #39
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I've got the same plans and I'm leaning toward the poly. My 35 year old plexiglass has all the stress cracks and spider lines I think you are talking about. Does the dealer have a time frame before the cracks show up?
He didn't. He said it depends on the radius of the curve. I tried to explain as best I could. He was not familiar with AS rock guards. He said no, and no warranty with that kind of bend.
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Old 04-13-2021, 08:18 AM   #40
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The comment about poly not enjoying being curved might be right although my poly guard has a curved corrugated surface, overall it is flat. These curves were probably formed with the plate warmed to be flexible. Installed in 2017, I have seen no deterioration in this product.
Yes, poly can be formed in a large oven, with tight humidity controls and a form, typically vacuum, but that can obviously only be done in a factory type setting, according to the shop owner. Bending cold is problematic.
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