PILOON
Super Star Member
Lexan or Plexiglass can be shaped.
I once formed an aircraft windshield by heating in a PIZZA oven and shaping it over the old one that I patched with bondo, wore cotton gloves and had clamps ready to clamp them together 'till cooled.
Possibly the other door (window) would serve you as a template as I would presume the curves would be the same.
Cut and trim using the door frame as your template.
Cut with a jigsaw and lubricate the blade as you go as the saw will clog and jamb and then shatter your plexi.
Then use glass adhesive sold at auto parts suppliers.
Should work OK, good luck!
I once formed an aircraft windshield by heating in a PIZZA oven and shaping it over the old one that I patched with bondo, wore cotton gloves and had clamps ready to clamp them together 'till cooled.
Possibly the other door (window) would serve you as a template as I would presume the curves would be the same.
Cut and trim using the door frame as your template.
Cut with a jigsaw and lubricate the blade as you go as the saw will clog and jamb and then shatter your plexi.
Then use glass adhesive sold at auto parts suppliers.
Should work OK, good luck!