I'm creating flush mount quarter windows
- Thread starter McClean
- Start date
Update,
I've been waiting on several samples of thermoplastic inserts to arrive for DT and NDT. They finally arrived for testing last week; I received two different versions (thread forming and press install.) The thread forming are by far the strongest and are the most resistant to pull out. The con for the thread forming are that they leave a frosted look to the poly that produce an eclipse look in the glass (see photos). I tried and tried and tried to overcome this issue to no avail (wasted 23 inserts at $2.77 per piece.)
I then tried the press install type of inserts. These proved to be impressive and lock in nicely to the poly. The advantage to these is that they leave very little evidence through the "blackout" and they install very easily.
I have a few different versions of the press install coming for testing. They should be here this week so I can complete the testing and finish the test pieces. I am working hard to ensure that these kits look as though the factory produced them.
See photos.
I've been waiting on several samples of thermoplastic inserts to arrive for DT and NDT. They finally arrived for testing last week; I received two different versions (thread forming and press install.) The thread forming are by far the strongest and are the most resistant to pull out. The con for the thread forming are that they leave a frosted look to the poly that produce an eclipse look in the glass (see photos). I tried and tried and tried to overcome this issue to no avail (wasted 23 inserts at $2.77 per piece.)
I then tried the press install type of inserts. These proved to be impressive and lock in nicely to the poly. The advantage to these is that they leave very little evidence through the "blackout" and they install very easily.
I have a few different versions of the press install coming for testing. They should be here this week so I can complete the testing and finish the test pieces. I am working hard to ensure that these kits look as though the factory produced them.
See photos.
Attachments
Instro84,
If you can get me the measurements as described on page 2 that would be great!
UPDATE:
I received the barbed press inserts last week and finally got to test with them over the weekend. The testing involves destructive and nondestructive measures. The reason I need to complete so much testing is because I don't want calls coming in about how cool the windows look while cartwheeling down the road.
The current configuration I'm using involves the barbed insert trimmed so that the entire barbed area is "biting" into the poly. Pressing the fitting into the poly in this manner locks it into the material and makes it very difficult to tear out. I have attached a few photos showing how the insert is installed and the view from the outside. This barbed fitting has the best appearance of any insert I've tested yet! I will be completing the very first set of windows this weekend and should have them installed (temporarily).
If you can get me the measurements as described on page 2 that would be great!
UPDATE:
I received the barbed press inserts last week and finally got to test with them over the weekend. The testing involves destructive and nondestructive measures. The reason I need to complete so much testing is because I don't want calls coming in about how cool the windows look while cartwheeling down the road.
The current configuration I'm using involves the barbed insert trimmed so that the entire barbed area is "biting" into the poly. Pressing the fitting into the poly in this manner locks it into the material and makes it very difficult to tear out. I have attached a few photos showing how the insert is installed and the view from the outside. This barbed fitting has the best appearance of any insert I've tested yet! I will be completing the very first set of windows this weekend and should have them installed (temporarily).
Attachments
highboostgn
Well-Known Member
- Joined
- May 24, 2011
very cool!
Update: Mission Successful
well after a lot of testing trails I think we are onto the final product. Before I get into the results I want to explain a little about the testing performed.
As explained earlier, I wanted these pieces to be as "bolt in" as possible. Some will need to grind a little here and there but for the most part these should be fairly easy to install. I have tested pull out force on the inserts. . . lets just say it maxed out one of my gauges and required bend the test piece of poly into a U shape before pulling out. With 5 studs for each window these should never come apart. I also tested the adhesion properties of the blackout "frit" area that needs to be painted. Maximum adhesion is reached after 120 hours at proper curing temperature. Adhesion between RTV and the painted substrate was also tested. I chose several different flavors of sealer. All performed very well and showed very strong bonding properties. In all tests performed I was unsuccessful at pulling the paint from the polycarbonate after full cure.
So now on to the final result. I have installed the final product into my vehicle (p.o.s.) for test fit and for photos to those wanting to see something. The left side of my vehicle is undergoing repair and currently only has sealer. The right side is needing repair and is waiting, so the paint on the right side is sorry as well. Use your imagination and pretend the car has nice paint.
Now that a final product and methods are complete I will be working with the Admin here and others to make these available.
well after a lot of testing trails I think we are onto the final product. Before I get into the results I want to explain a little about the testing performed.
As explained earlier, I wanted these pieces to be as "bolt in" as possible. Some will need to grind a little here and there but for the most part these should be fairly easy to install. I have tested pull out force on the inserts. . . lets just say it maxed out one of my gauges and required bend the test piece of poly into a U shape before pulling out. With 5 studs for each window these should never come apart. I also tested the adhesion properties of the blackout "frit" area that needs to be painted. Maximum adhesion is reached after 120 hours at proper curing temperature. Adhesion between RTV and the painted substrate was also tested. I chose several different flavors of sealer. All performed very well and showed very strong bonding properties. In all tests performed I was unsuccessful at pulling the paint from the polycarbonate after full cure.
So now on to the final result. I have installed the final product into my vehicle (p.o.s.) for test fit and for photos to those wanting to see something. The left side of my vehicle is undergoing repair and currently only has sealer. The right side is needing repair and is waiting, so the paint on the right side is sorry as well. Use your imagination and pretend the car has nice paint.
Now that a final product and methods are complete I will be working with the Admin here and others to make these available.
Attachments
Charlief1,
I can take a photo of the damage. The insert would not pull out with the substrate under zero deflection. It literally required pulling the substrate at each end, bending the test piece into a complete U shape. When the test piece was at roughly a 70 degree angle the hole that the insert was pressed into deformed along the X-axis creating a loss of surface area contact. This is when the insert actually lost grip and tore out. I can tell you that I weigh 215lbs and it took me pulling with all my weight to produce this effect. Now multiply that holding power times 5 and you have a window that will NOT come out.
Thanks for all the positive comments!
I can take a photo of the damage. The insert would not pull out with the substrate under zero deflection. It literally required pulling the substrate at each end, bending the test piece into a complete U shape. When the test piece was at roughly a 70 degree angle the hole that the insert was pressed into deformed along the X-axis creating a loss of surface area contact. This is when the insert actually lost grip and tore out. I can tell you that I weigh 215lbs and it took me pulling with all my weight to produce this effect. Now multiply that holding power times 5 and you have a window that will NOT come out.
Thanks for all the positive comments!
ShaunDonWe2
Member
- Joined
- Apr 30, 2012
Nice, excellent work and craftsmanship