clear sheet styrene

[forthlin]

I'm building a Palmer '63 Pontiac Bonneville that doesn't come with a windshield. Would a .005 sheet of plastic be thin enough to conform to the window frame? If not what is a good substitute to use?

[Ace-Garageguy]

.005" or .010" should do you fine.

Unlike some other cars, the '63 Pontiac windshield has a very slight compound curve, almost negligible.

Because the apparent curve is only in one plane (as evidenced by this profile view), flat sheet stock should give you a good looking solution.

Edited February 12, 2022 by Ace-Garageguy
CLARITY and ACCURACY

[forthlin]

Thanks. I thought it would but I wanted to make sure before ordering it.

[NOBLNG]

 

22 minutes ago, forthlin said:

Thanks. I thought it would but I wanted to make sure before ordering it.

You could try some clear packaging plastic first to get an idea of whether or not a flat piece will conform to the shape needed. Even thin plain white styrene if you already have it, or some stiff paper like a file folder would work.

[Ace-Garageguy]

There's at least a partial how-to by Bill Geary (Mr. Obsessive) somewhere on here showing how to make a simple single-curved windshield from sheet stock, and making up retainers on the pillars so the "glass" will just snap in place once it's made right.

I usually use masking tape to make the first template, transfer it to .010 white stock, get the fit dead on, then transfer that to the clear stock.

Works flawlessly every time...but NOT for compound curves (it WILL work on the '63 Poncho).

[Bainford]

As Bill mentioned, either .005" - .010" will work well. I prefer the .010" myself. I find the .005" to be flimsy and aggravating to get a nice, consistent curve across the windshield. The .010" is firmer and much easier to work with. For a first attempt at making a windshield I would recommend at least .010".