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The Pro Glass Lexan windows were delivered covered in a protective film. In case you’re wondering, this is why they appear foggy in these pictures. The protective film was removed after we completed the car's construction.
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Costa also completed the installation of the rear and quarter Lexan windows. It’s standard practice for Lexan windows to be manufactured slightly oversized so they can be trimmed specifically to size on the car. Costa carefully trimmed the windows down to size and then drilled equally spaced holes around the perimeter of the window.
Each of the holes were drilled slightly oversized to allow for slight misalignment and more importantly, the expansion and contraction of the lexan with temperature changes. Too tight of a fit between the bolt and the hole can cause a crack to initiate in the hole and propagate across the window. For each hole, Costa drilled a complimenting hole in the body of Project 240SX LSR. He then used a knurled rivnut (threaded insert) to allow each window to be fastened in place with a stainless steel button head allen bolt.
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Here’s a little trick that we learned from Scott Dodgion of SPD Metal Works. We purchased a roll of adhesive backed Velcro “loop” from McMaster Carr and placed it between the body and the Lexan to act as a cushion and to help keep dirt from getting into the car.
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Annie Sam used this crazy industrial hole puncher intended for scrap booking and other girly crap to punch holes in the strip for the bolt holes. Don’t let the pink handles fool you though, this thing is on steroids.
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By this time, Costa had to return to preparing Matt Powers’ drift car for an upcoming event, which left John with the responsibilities of the door windows. The windows in the doors of the S13 are a bit more challenging since they are frameless in construction, lacking support around 75% of their perimeter.
