Getting started on the choptop truck...

[FORDification]

Well, I'll definitely be researching the custom-glass angle, to get an idea of how much this would be, and whether it works for me.

As for Lexan, that thought crossed my mind, but Lexan isn't DOT-approved for use on windshields. DOT and state regulations require the use of laminated safety glass for the windshield, though using Lexan for the side and rear glass is a very viable option. Of course, that's not saying I couldn't use it for the windshield, but I could run into problems with it if someone with a badge has a good eye.

Lexan is used in aircraft and choptops that were not done properly...like mine. It's actually very inexpensive though...I could get a sheet large enough to do the windshield for about $200 from Jegs...but it would still need to be formed, which would be a tricky proposition. I ran into this thread over at HotRodders.com where someone was describing how to do this:

Make the first template out of 1/8" tempered Masonite and cut it a little larger than needed and use a disc grinder to fit it close and then file fit or use 80 grit paper to final finish. Use small ribs made from plywood, glued and brad nailed to the Masonite on the inside of the curve to complete the shape. Lay your Lexan over the Masonite allowing 1/8 of an inch overlap on all sides. Put 1/4" carriage bolts with large washers in the bottom and bend the Lexan over your 'buck' and use large paper clamps (with taped edges, so as not to mar the Lexan) along the top and sides. Pre-heat your oven to about 350 degrees and pop it in, taking care as not to touch the hot metal surfaces inside. Heat it up for 10 to 15 minutes, turn off oven, open door and let cool for 1/2 hour. Remove from oven, CAREFULLY remove clamps and allow Lexan to relax until it is at room temperature. Remove bolts from buck and see if it retains its desired shape. Trial and error on the time, but don't go over 350. Keep the rack of the oven in the middle....

Of course, I don't happen to have access to an oven large enough for a windshield, so I don't know...I've got some time, so I'll just keep researching and see what turns up.

[layedout72]

If you have an oxyaccetelin torch, it would probably work the same... just a "loose" flame, and going over the entire area for a few minutes.

As for the laws, does it say a "motor vehicle" or a "car" or "automobile" or whats the word they use to refer to what its on. If it says car, you may be able to get around that, being as you drive a truck. It may also have a loophole for custom cars.

[Pipes71]

I cant really see how the bottom and the sides fit but is it possible to belt sand the bottomcorner of the windshield to change the angle so it brings the top of the glass in? I'm not sure how much play you can get with the rubber,but maybe it can be enough to bring it close to the top and if worst comes to worst you could fab something up easier to cover the bottom of the opening more so then the top. maybe like an inch or two of metal molded around the bottom of the windsheild opening blending in with the body, so you can angle it enough to fit.. just throwing this idea out.. I'm sure when I go outside in a few to uncover mine up I'll slap myself in the head and say that won't work..

[fordman]

As for the laws, does it say a "motor vehicle" or a "car" or "automobile" or whats the word they use to refer to what its on. If it says car, you may be able to get around that, being as you drive a truck. It may also have a loophole for custom cars.

more than likely it says motor vehicle.

[flyboy2610]

Don't use the Lexan. By the time you put the money into making the windshield, and then paying fines and court costs when you get caught, you'll have spent more than what a custom windshield would have cost in the first place. And then you still have to get the windshield.

[ladz]

Hey Keith, i was thinking about the oven not large enough you can make one with large metal duct and a propane heater !

[460 crew]

Is there laws on how large a windshield has to be? You could fill the windshield area in and open a slot about 6in tall about 3/4's of the width of the original window for a small windshield and have a kinda road warrior/vigilante look. Just large enough to break out and pop an automatic weapon through when the world goes to poop.

[Pipes71]

[rjewkes]

what if you cut the windshield at the bottom would it fit closer at both ends i wonder?

[FORDification]

If you trim the glass from the bottom, then the bottom would be too narrow. It fits perfectly down both sides and along the bottom right now, with the trimmed version....it's just that the curvature wasn't taken into account when doing the chop, so the top doesn't match.

As I see it now, the only options I have are to either get a custom (mucho $$$) windshield made, use Lexan and keep my fingers crossed that nobody notices, or spend a bunch of time reworking the upper windshield channel, to extend it out several inches to match the cut-down factory glass.

[ladz]

Have you looked into a different year windshield that may work i am not sure but didn't the galaxy rap around like the f-100's or split the middle

[layedout72]

keith what about a little sun visor like some of the traditional rodders use? after all, thats sorta the "theme" your after correct? You could make a channel for the windshield to seal it, then just have a small "visor".

[Pipes71]

just thinking out loud here.. but is it where he sectioned the windshield pillars thats throwing it all off?I was looking at mine and it seemed the pillar had a slight curve.. just wondering if the PO sectioned the pillars at the wrong spot then that could be the problem and maybe just cutting them out and finding a donor cab to cut out another set of pillars ,match them to the windshield then cut them to size and weld them back.... I'm sure ya thought of all of this..but your projects keep my mind spinning with things I want to do to mine and well...

[dablack00]

If you are going to put it on the back burner and finish the red truck I see one of two things happening here. You are going to finish the red truck and then leave the chop in the back of the shop for the rest of your life, or you are going to finish the red truck and then rework the windshield channel to fit the cut down glass. Don't even pretend to use lexan as you know that would bug you to death that you didn't do it "right". Don't even pretend to say you are going to buy a custom windshield because that goes against the whole point of the truck. Push the chop in the back, finish the red truck and decide what you want to do. Either it will be done right, or it will be done right by one of your kids. Any other option just doesn't fit you.

I'm not telling you who you are or what to do, but from what I've read, I think I have you pretty well figured out. Not doing it right would bug you to much, even on a "trash" truck.

Austin

[ladz]

Yo pipes , i was looking at the same thing , but then the door jam issue!