As I said in my original post (or at least meant to imply), I know pretty much nothing about lexan, and have just started looking into it.
I will weigh everything! The point of going to Lexan is to reduce weight. If it isn't that much lighter than glass, I won't bother. I had read that lexan in the same thickness as glass is about 1/3 weight. But it sounds like that source was unreliable.
The rubber moulding on the Scirocco is not that substantial, and I would be very surprised to find out it weighed more than the window glass, especially in the hatch. But the only reason I had thought to keep the original width and reuse the rubber seals was to keep the car from leaking. I do not yet have a permanent garage -- it lives in a tent (aka the ghetto garage
) -- but even if I did, I'd still like to keep the car waterproof. But maybe pop-riveting and caulk will be enough to seal it.
Anyway, I have a good place to start. Thanks for the info, and I definitely will look closer at the weight / thickness...
Grace
