SwampThing

Well, finally got me another top for my 4Runner, but now I need to find me a good place get some plexiglass (gas fumes just blast on in now cause the glass in tailgate shattered). But my tailgate is so dented, if I just put in a replacement glass panel, it wouldn't be able to roll down.

Thinking about just cutting some plexiglass to fit, slide it in, then rig up some little bracket deal to make installing/removing fast and easy...

Anyhoo, here's a couple pics to see how dented my tailgate is. Its actually a much worse now, a couple of my bud's backed thier boat into my tailgate.



Btw, my new hardtop is line-x'ed in black just like the top portion of my cab. Pictures of that later.

CJM

Make a plexyglass panel that will fit and either attach it using a snap type system or the easier and less annoying way would be to fab some sliding brackets and just slide the bracket down when you want it out.

Elton

show off

SwampThing

Well, if I did a slide down style bracket, when we tailgate, the window would now be in the way even with the tailgate down... Was thinking about doing something like how jeep windows use those really thin hydrolic thingamajigger to make it open up and outwards, but I have no idea how hard that'd be...

CyMoN

if you cut the plexi to fit in the topper the all you would have to do is drop the gate and slide the plexi up and close the gate to hold it in.

SwampThing

Hmm, your idea sounds the simplest Cymon. I'm liking it.

So, now where do most of yall get your plexiglass, and what do you use to cut it? All I could think of that I have that would cut it would be my diamond blade on my jam saw...

CyMoN

dont know where i would get it but iwould get a stanly shark tooth hand saw mark out your lines and cut by hand i have found that sawzaws jigsaws and circular saws thend to chip or crack plexi if you take your time and go slow with a hand saw you get better results. also make sure to go about a 1/8" larger than what your finnished cut is to be so you can sand it down for smooth edges

it will slide alot better.

i also bet you could rig up a pull cord on your gate so that you can open it from the outside that way you dont have to climb in the back to open the gate.

SwampThing

Good idea. Yeah, I'm a floor man, and we use these diamond blades on our grinders (basically a dremel) to cut real delicate materials like ceramic, porcelain, marble, and other natural stone tiles that chip and crack real easily. I'll probably cut off a little section to test how my grinder does on it, but if it doesn't work that great, I guess out comes the hacksaw!

I'm just wondering how much a plexiglass sheet that big will cost... Cause I just about wiped out my disposible income for this week from buying that top and having it line-x'ed lol...

CyMoN

last time i had looked it was not cheap but some times you can find a lighty sracthed one at a glass shop for cheap or free.
also google it..

aviator

For cutting plexi glass you can use a jig saw with a medium blade, what you want to do is put masking tape on both sides and draw your cut line on the tape, don't push to hard as its the directional change that causes the chipping. To cut it without chipping you want to use a band saw. In any case you want to cut a little proud [outside of the line] then use a sander [belt is best] to remove material down to the finish [cut] line. If you use this method any chips will not matter and you will be left with a clean edge, just dont sand to long in one place you don't want to heat the plexi up too much as it will become soft.
Hope this helped Aviator

Robinhood150

I don't know if you have OSH or Tap Plastics over there in Texas but that's where I've gotten mine. Do a google search for plastic suppliers and I bet there's something around you. If not, your best bet is www.mcmastercarr.com

I've tried the jigsaw thing, but it leaves rough edges which eventually lead to cracks. I believe the right way to do it is to scribe a line and break it off like glass, but I haven't tried it. Of course, you can't do this for curves. The jigsaw does work, just be sure to sand down the edges real well.

You do not want to use any high speed saws like angle grinders, dremels and such. They just melt the plexiglass and end up gumming up your blade.

SwampThing

Thanks yall! Keep the thoughts flyin! Been very helpful so far.

95RunnerSR5

i dunno if this applies there BUT!....after the hurricane, Northrop Grumman's shipyard was tossing out plexi by the truckload, most of it was in perfect shape so we grabbed it, full sheets from 1/16" thick to 1/2 thick, most is gone now. maybe you can check around down there for tossed out stuff....

SwampThing

Well, still having trouble finding plexiglass... Went to Lowes and Home Depot, and they just looked at me like a cow lookin at a new fence. "Uhh, maybe you should try radioshack." Uhg...

CyMoN

if you have a truck topper company like LEER near you they use plexi in those toppers alot try them.

doc76239

try one of those rotary zip saws. Trying to remember the dam name. You see them on info mercials let at night. We used on for cutting plexi glass when I used to build boats for Meridian yachts AKA bayliner yatchs. Just tape both sides before cutting.

SwampThing

Ohh good idea cymon & doc. Theres a top place real close, so I'll check that out, and that rotary zip saw is almost exactly what I had in mind for cutting it. So, what kind of tape is preferable? Duct, masking, scotch, packing, ect...?

91 4Runner

Make a cardboard template and take it to a glass/window shop and have them cut it... That's what I did, and it only cost me $40.00 canadian for 1/4"