First Gen back window

[Bent77]

So the Bent '72 all but spit out the rear glass last winter, and the fiberglass hatch finally gave up the ghost. So my idea for a new back window is a single piece clear plastic with a fabricated window frame.

Any ideas? I have a few, like using 2 1" straps down the hinges to the bottom for support...

 

[Bent77]

My Starting point. Going to reuse the factory hinges

Tacked at the ends and in the middle. Using 3/4" x 1/8" angle

making sure it dont looki Hill Billy

 

[Bent77]

I tacked it here...

And here. Going to weld these on the back where i dont have to grind and the window will sit flat.

Once the window is in place, I plan on sectioning the hinges to adjust out the thickness of the window, and plan on making 2 small gussets for each hinge to help bear the load and stress to the top part of the frame

 

[bigbadchev84]

Why not just repair the old one? Looks like you are trying to re-invent the wheel. I had one that was nearly broke in two, I took the glass out, split it in half, repaired the broken fiberglass from the inside, glued it back together and had a perfectly functioning hatch again.

 

[Bent77]

Mine was extremely bad, and after many fiberglass repair session, it wasn't going to happen.
Most of the damage was by the hinges and the struts on the side


And the added bonus is getting to have a back window that is not obstructed by the outside fiberglass.

Here I made 1 slice down the center to help adjust toward the slight crown. I also made a cut outboard of each hinge to transition easier into the corners

New corners! I made 3 slices at a time before bending, working my way around. Once I had enough length to get past the corner, I re-sliced some of the inside cuts to match out the radius.

 

[Bent77]

Here I am marking the top of the corner pieces to match out the tie in cut

After this I cut the tack welds along the bottom, and open the window frame enough to cut the top pieces to match the corners. I then notched out the bottom of the corner pieces to match the bottom runner

I finished the tack welds, then cut my tacks off the hinges. Now to weld up all the slice cuts and smooth off before fitting the window

 

[gaspass]

If you want I have a complete hatch with glass I'm willing to let go. It came with a beat up top I cut into a half cab.

 

[bigbadchev84]

If you want I have a complete hatch with glass I'm willing to let go. It came with a beat up top I cut into a half cab.

I would be interested in this, Please email me at [email protected] Thanks!

 

[Pizza_Man]

I'm really interested in how this turns out! I've been without a back hatch for almost 2 years (truck didn't come with one) and I've been dying to make one but never knew what direction to go. But I dont have any hinges or latches or anything. I can't wait to see how this turns out

 

[Bent77]

Workin on it! got some photos but left my welding hood on the work truck at the shop so didn't get the progress today I wanted.

Have the hinges sorted out, just need a latch system...

 

[Bent77]

Word of note: when I laid out the steel for the frame. I gave myself some overlap so the screws thru the window frame don't hit the fiberglass.
But if you use a weatherstrip, most will squish enough if the bolt or nut is between the frame and the fiberglass that it doesn't rub the fiberglass.

After welding up the seams and grinding them, I lay the sheet of plexi on the steel frame to trace out where I need to cut it.
The sheet I am using is .220.

There is a cutter designed for the plexi, but I opt to cut it with a cutoff wheel on the grinder.

After Cutting it, I carefully drill the holes thru the plexi while it is in the frame.
I only dimple the steel with the bit, opting to drill it separately so not to damage the plexi in any way.
I come back and use the dimple marks to drill where the plexi matched the frame.

 

[Bent77]

After drilling all the holes, I removed the window and slid the frame back in place.


Check the bolts to the hinges at this point (inside the topper where the hinges slide in). Mine are notched for some adjustment, so I slide them forward enough that i can slide them out after I weld to adjust for weather stripping. this will keep the frame tight and flat against the topper so the weather stripping gap will be even later once the hinges are slid toward the back.

Taking the cutoff wheel on the grinder, i cut the hinges off flush on the 2 short sides of the factory mount to the original hatch.
This allows me to tack the frame directly each side of the pivot points.

With each side of each hinge tacked, I now lift up the frame to weld the back side of the frame to the hinges, then close the frame to weld the front.

Here's the pic of that ready for paint.

 

[Bent77]

Once the welds are cleaned up, a fresh coat of black paint.
Then I pull the protective plastic off both side of the window and line it up.

I chose to use #6 machine screws in Stainless rather than rivets, so as to better control the amount of tension applied to the window

With a little Loctite, they find a happy home:

Next i will need some latches