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Just got the new overcab wraparound windows—gray tinted plexiglass!  I plan to install them tomorrow with the new trim we ordered and the new sealant. Any tips, tricks, suggestions for an easier/better/less frustration-filled day would be appreciated!  

Wish me luck!

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4 minutes ago, Derek up North said:

Can't offer any tips but would like to know where you sourced the windows and seal. :)

@Derek up North

Seals came from a company called Grainger www.grainger.com. They are Trim-Lok gaskets and come in two parts—the locking gasket and the key, which is a separate purchase. 

Item #s 10G547 and 10G561 respectively. The customer service was great—we sent pics of our gasket and measurements and they sent samples to confirm. It comes in different lengths—We bought 25ft. 

As for the windows, we purchased the plexiglass sheets (bought extra to make an extra set and for possible breakage) and measured and made patterns ourselves from the originals. We cut them out with a scroll saw blade on a jigsaw and used a plywood overlay with clamps for stability and to avoid cracks. 

We then took these cut windows to a thermoplastic company here in North Carolina and convinced them to bend them for us with their equipment for a fee—came out great—looks like a perfect fit!  I can see if they are willing to make more now that they’ve done it?

We tried to order windows from another company in California, but they wanted $700 for the two windows with shipping!  We had to be creative...  :) 

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16 minutes ago, Derek up North said:

Well done for your solution. How much do you figure you saved? Did you consider using Lexan?

My first consideration was actually using Lexan, but after researching the pros and cons, opted for plexiglass. Lexan is break-resistant and therefore amazingly flexible to mold and I would have bent the windows myself if I had used it but it is not scratch resistant and tends to fade in sunlight. Small aircraft will use plexiglass in the front and Lexan for side windows and doors. 

Panels were about US$100 and you could get 4 windows out of a panel if you were careful...  The mold and bending—another $100. Saved $US500 minus gas to and fro. 

If you can reuse your gasket—great, but the California windows for $700 didn’t include gaskets either...  

 

 

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please post pics after install. i admire your problem solving AND saving a bunch of money. great work. joe from dover

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Finally getting to post the completed window pics. Must say that it was harder than I anticipated, requiring my recruitment of another pair of hands and borrowing some handy glass holding tools to use as suction for pressure and/or pulling at times—I had to start over a few times because it kept slipping back out without another person to help. Also invested in a plastic tool (see the blue tool) to work the locking gasket and another tool to set the key.  I think they don’t look too shabby!

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Edited by WenSun
Added pics

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look great. really nice. joe from dover.

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yes it is as good as advertised. working in a retail and commercial cabinet shop, I have used lexan poly carb sheets in making high end display cases.  it will adapt to many uses that previously only glass was considered. has many additional benefits as well. (I.E. bendable.) joe from dover.

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@Derek up North @hunkaman

Reading the description:

“Due to its mar-resistant coating, this product cannot be cold-formed and is intended for flat applications only.”

performs extremely well for other flat applications such as view windows and machine guards in harsh chemical environments.”
 

It sounds great but is it still heat moldeable and without losing its coating benefits?  Anyone know the price point in comparison to plexiglass?

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the lexan poly carb material I am familiar with is formable with heat. joe from dover.

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