Plexiglass or other option

[dave92cherokee]

Did some searching but didn't really find anything besides people wanting to make windshields after busting them out. I'm looking to make a custom shaped side door and as such neither front nor rear window will work so will need to be custom shaped. Question is for a DD how well would plexiglass hold up if cut to size and mounted in the door in place of the regular glass? Or would it be better to try and hunt down a company that can make automotive glass in custom shapes and sizes? I know plexi scratches easily but would it get scratched up just being in a door and rolling up and down without seeing any trail action?

Edit:
Something to fill in the back window in a configuration like this with 1 solid piece.

 

[WrenchMonkey]

That window is wider at the the top than the bottom.

It won't roll down.

Robert

 

[dave92cherokee]

Yah I might just use the regular window from the back door and then make a custom plexiglass piece to fit inside of the small fixed window.

 

[jodaddy]

My friend did her first chop top and learned the hard way. Easier to find or cut glass first to build around. Maybe try an old full size grand wagoneer window.

 

[tbburg]

'Kinda curious what the application is. The straight back window needs a full length door all the way down the back edge to roll down. The reason for the filler window in the back door is because of the cutout in the door at the bottom to clear the wheel well. So what's the project? Stretched 4-door XJ or Crew-cab MJ?

 

[winkosmosis]

Why do you want it to be one piece?

 

[GrimmJeeper]

with plexiglass anything less than 1/4" thick is going to vibrate and wiggle around enough to be seriously annoying, even when fully raised. the scratching is a non issue, when sealed properly plastics are nearly as scratch resistant as glass- the problem is nobody cares to take it that far. even with 1/4" material it starts to get iffy beyond a 12" span or so. not sure material that thick would even fit in the stock channels.. acrylic might work but you are looking at over 200$ to cut and form a piece of acrylic to match that space, why bother? if money is no object go for it!

 

[Talyn]

Plexi and Lexan that one can buy easily are not scratch proof or even close to scratch resistant as glass.

 

[96TNXJ]

could you use a window from a 2 door XJ as the doors are longer

 

[dave92cherokee]

There's the other possible way I could do it so the window would be the small fixed window and be cut from a small piece of plexi. And for those curious tbburg hit it right on the head I'm going to be building a 4 door mj.

 

[WrenchMonkey]

I'm going to be building a 4 door mj.

You're making it way too hard on yourself:

Using four stock doors, and the factory MJ longbed wheelbase.

Robert

 

[dave92cherokee]

There's the one that I'm going to build hence the full length rear doors. The back of the xj's rear doors curves forward and the mj is the same as the front doors and curve backwards. So trying to avoid major modification to the rear of the MJ cab and keep the full door design instead of the weird shape for the rear doors.

 

[Talyn]

The second one looks much better

 

[dave92cherokee]

Yah I'm trying to build the blue one but hoping I can get lucky and find a 97-99 xj to use for the front. Not sure what I'm going to do for the back seat since the xj's back seat is shaped weird for the wheel wells. Might look at mounting an MJ bench in the back since it would go all the way from side to side. If anyone has an idea for the rear seat to use that will look good and fit 3 kids let me know.

 

[WrenchMonkey]

There's the one that I'm going to build hence the full length rear doors. The back of the xj's rear doors curves forward and the mj is the same as the front doors and curve backwards. So trying to avoid major modification to the rear of the MJ cab and keep the full door design instead of the weird shape for the rear doors.

I understand what you're trying to do.

But in that pic, both doors have vertical trailing edges. That's just not how either door is really shaped.

Don't use that pic as your model. Everything would have to be made from scratch: Door panels, windows, window frames, rear cab, stretched "frame," everything.

Robert

 

[winkosmosis]

I think it's going to be nearly impossible building a door that seals properly. Just use regular doors, or a second pair of front doors mounted backwards

 

[GrimmJeeper]

Plexi and Lexan that one can buy easily are not scratch proof or even close to scratch resistant as glass.

it can be sealed, covered with clear vinyl, etc. there are options, but you are correct. left untreated most plastics available in sheets scratch if you look at them wrong.