P500 DIY Aluminum Frame Window with Glass

[JCart]

Hey Fellas and Ladies,
Finally go around to messing with an aluminum frame made from 5051 1/8” aluminum sheeting. After measuring, chewing on it, measuring several more times, bit the bullet and took it to a shop to get a professional break done to the bends as I don’t have that. I wanted to create some bends to add rigidity to the frame. Glass will be automotive type S2 safety glass that’s 1/4” thick. Be held in with “J” quality rubber tube type glass seal. To hold onto the ROPs cage, I’ll repurpose my Honda factory ROPs clamps they are a great product. No provisions for tipping up just yet, but will be making something to get under the hood. The seal between bottom of window frame will be black UHMW riveted to the window frame.

The sides tuck over the ROPs tubes by about an inch... (again to create stiffness in the frame) which causes some concerns and I may cut slots so I can remove frame via ROPs clamps.

 

[trigger]

Nice! I've thought about doing it too but don't run a full shield enough to justify the effort. Keep us posted.

 

[Bigtee]

Looks good. I love to see people create. Definitely keep us posted

 

[JCart]

Thanks fellas, cost here in Canada for this type of stuff pre made is.... well I’d rather buy the tools and supplies and mess about then you get what you want and it’s kinda fun too. I left enough space on the sides that I’m thinking I can have some sort of door enclosure fit between the the ROPs and the windshield frame and/clip to the aluminum lip. Dropped it off at the glass shop should be done next week. I’ll toss up more pix then.
Cheers

 

[JCart]

Trial fitment and install of lower vent flap. So far so good, I’m pleased with the way it fits and the UHMW vent flap at the bottom will work great. Can even manage the hood removal, just raise vent flap. It’s a snug to remove/install but overall pleased.

Not ran it WOT or hauled yet but I’m thinking there’ll be very little frame/glass defection. Glass could have been total 1” wider but at the time was concerned about frame/glass defection with wind pressure. Now just tape off window aluminum primer then gonna final with spray black undercoating I think.
Cheers.
j

 

[JCart]

Pretty much completed window, used aluminium etching paint then spray black undercoating. Nice to have a clear view. Ran WOT on the highway no noticeable flex so we are good to go. Will look for manual wiper(s) soon.
Next up is Moose trailer hitch then hook up harness to 10 watt (each) LEDs in above winch.
Cheers
j

 

[SORGuy]

I also did a home designed glass windshield with aluminum frame. Mine looks homemade with 3/4 inch angle iron welded to 2 inch flat aluminum attached with hose clamps. Local auto glass shop cut the glass to fit and it works well, even if is not pretty. Glass is the way to go.

 

[bowhunterbill]

“There’s no points for pretty out here, Bill”

- My son’s buddy said to me commenting on my welding on a hone built duck hunting decoy cart.


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