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Old 12-28-2010, 09:58 PM   #1 (permalink)
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Help forming Lexan roof extension - updated, final version

Just got done making this frame, my previous roof extension was just a prototype... But I am not sure how to form the Lexan to it. Would it be smarter to cut three pieces? Any ideas on how to join them? Thanks!




Last edited by Jesse; 01-17-2011 at 04:11 AM..
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Old 12-28-2010, 11:10 PM   #2 (permalink)
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How to heat and bend Lexan | eHow.com
I have used a heat gun (HD air dryer) for small pieces, you have to be careful not to snap it. Looking at your frame, the low angle bends are probably OK

Careful of the fumes :P
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Old 12-28-2010, 11:55 PM   #3 (permalink)
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I love the design - would love to see how it performs. The leading edge will have to be sealed very well all the way around or it will rip its self off like a parachute. Just an idea but maybe a lexan window for visability and fiberglass the rest ? Looks good !
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Old 12-29-2010, 06:49 AM   #4 (permalink)
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Had to rush it since I work today and don't have a heat gun, decided to cut it into three sections. I am trying to think of a way to sandwich the pieces in between some aluminum strips or something thats clean and not red green engineered aka duct tape!

My first roof extension had no curve and was a 12º angle, this one is curved but is steeper, in around 13.5º. 11 inch drop over 48 inches. Sides are a at about 11-12º


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Old 01-17-2011, 04:10 AM   #5 (permalink)
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Completed version





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Old 01-17-2011, 06:26 AM   #6 (permalink)
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Sweet!
I'd love to see that tested. If you have time, then maybe A-B-C-A-B-C testing, where you also cover the bottom (Orange4boy tried that, I believe).

How heavy is the whole thing?

I take it that it is opaque because of temperature/snow issues and it will clear up?
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[Old] Piwoslaw's Peugeot 307sw modding thread
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Old 01-17-2011, 08:17 AM   #7 (permalink)
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Quote:
Originally Posted by Piwoslaw View Post
Sweet!
I'd love to see that tested. If you have time, then maybe A-B-C-A-B-C testing, where you also cover the bottom (Orange4boy tried that, I believe).

How heavy is the whole thing?

I take it that it is opaque because of temperature/snow issues and it will clear up?
I was planning on doing some tuft testing. It's opaque because of salt.. I have thought about sealing mine up as well, less vacuum inside the roof extension I suppose? Would help keep it clean at least.

My problem is I can't do a pure aba test. I can do with and without the roof ext.

When I started ecomodding this past August I never thought I'd go so crazy. I can't re install all the mudflaps, pass side mirror and moonroof deflector because I disposed them. I could re install the rear wing... I dunno. I don't really care if people believe my before and after FE numbers, I just care if they increase my mpg, and save me money post ROI. I just know what I used to get during winter/summer months(owned this vehicle since Oct of 2007) and I always check my mpg(pump fill vs odo reading). With no warm up times I could get 29-31mph in the winter depending on temps and how I drove it(conservative vs driving like I stole it) and usually 32-34 in the summer. Granted it's only one tank, but in single digit temps I haven't gone below 38mpg. Now bad seeing as I don't do any of that crazy engine off coasting or anything.

Great, I was thinking of sealing it up, but now since I searched on here for sealed vs unsealed, really want to seal it! Thanks LOL

Last edited by Jesse; 01-17-2011 at 08:26 AM.. Reason: comment addendum subsequent to reading about sealed extensions
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Old 01-17-2011, 08:56 AM   #8 (permalink)
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Nice work


Next step : a lower fairing to match the top
You know you want to
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Old 01-17-2011, 04:19 PM   #9 (permalink)
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Super slick results! How did you get the compound curves on the side pieces of lexan?
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Old 01-17-2011, 05:59 PM   #10 (permalink)
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Jesse, I'm going to have to have you help me remake my lexan Kammback for my VX this summer! That looks great!

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