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Old 11-15-2010, 10:00 PM   #1
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$75 Hard Top Glass

My YJ came without the back glass in the hard top and I wasn't about to spend $350 - $500 for the glass when I could make one for $75. My purpose for the back glass wasn't to keep thieves out.....just the weather and the gas cologne...

Start out by going to your hardware store of choice and pick up a 36" x 72" x .223 Lexan. While there, have them cut a few pieces to size...

Main Glass - 47" x 26.5"
Lower Reinforcement - 44" x 4.5"
Hinge Reinforcement - 5" x 2.5"

While you're there, pick up some stainless fasteners....

3x 1/4" x 1/2" stainless bolts
3x 1/2" stainless nuts
2x 1/4" x 3' stainless bolts
6x 1/4" stainless small washer
4x 1/4" stainless medium washer
4x 1/4" stainless washer / nut combos

Also, pick up some 1.5" x 3" flat stock to use as locks....I'll explain later.

Get beer.....whatever you drink.

Tools required - sockets and dremel / die grinder with cutting bit and fine / rough sanding disks.

Trim the 47" x 26.5" piece of Lexan to a trapezoid shape that's approximately 43" at the top on center and 26" near the edges. Use a black magic marker to trace the outline of the opening as a guide. Cut the Lexan to size then fit the piece into the glass opening and fine tune as necessary. Take your time here with the cutting bit as the Lexan will melt and form cooled build up if you rush.

Line up the glass hinges and gradually drill a 3/4" hole to allow the hinges to attach to the Lexan. Take your time here....drill slow as Lexan melts and will crack if you try to hurry with the larger bits. I used a gradual dremel sanding bit to fine tune the holes. Once you are finished here, cut 3/4" holes in the Hinge Reinforcement Lexan pieces to match those you just cut in the main piece. Attach the Lexan and Hinge Reinforcement pieces to the hinges and tighten as necessary using the mounting hardware that came with the hinges. Don't tighten the hinges to the shell just yet as you need to check for clearance and fine tune the Lexan as necessary. Once it all fits, tighten the hinges to the shell.

Moving on to the bottom, drill a 1/4" hole at either end of the Lower Reinforcement piece of Lexan approximately 2" from the bottom and 1 1/4" from the sides. Again, take your time here... Once the holes are cut, lay the Lower Reinforcement piece over the main piece approximately 1" from the bottom and center it with apprxomately 1.5" clearance on either side. Use the holes you just cut into the reinforcement piece to drill holes into the main window. Yep...take your time.

Once the holes are cut into both pieces, thread 3 of the small washers onto the 3" bolt followed by 2 of the medium washers. Thread this unit into the main window, then into the Lower Reinforcement behind it. Once this is done, thread one of the washer / nut combo's backwards onto the bolt approximately 1/2" from the end of the bolt. Take the flat stock you picked up and drill a 1/4" hole 1/2" from the end, centered 3/4" in to form the locks. Do this twice. Thread the flat stock onto the bolt, then secure it with a washer / nut combo threaded correctly. Repeat for the other side.

Finally, on the lower reinforcement, drill 3 1/4" holes 2" in from either lock and in the middle of the window. This will ensure the lower reinforcement stays in place and reinforces the bottom end.

Depending on your tail gate, you may or may not have the lower weatherstrip. If you don't go to Lowes, Home Depot, etc... and get something similar to form a seal at the bottom.

Done... it seals, keeps the weather out, and best of all cost you $75 an a couple hours of time.

Finished Product - 2 hours start to finish.


Hinge Reinforcement


Lower Reinforcement


Lock Mechanism


Center Support Bolt


Lock Support Bolt


Turn the lock to lock / unlock

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Old 11-16-2010, 12:01 AM   #2
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Now all that top needs is some new paint!

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Old 11-16-2010, 07:55 AM   #3
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did you use and special blade to cut the lexan?
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