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Here's some pictures of my sliding windowconversion.
After many elaborate plans, curved tracks, latches, seals and much input from forum folks (Thanks Joel), in the end I decided to keep it simple. I cut a big hole in the original one piece window, added some felt strips, and fitted a movable window over the hole. Works great.
The hole is the old window is at the Lees elbow position (aft) roughly 12X12. The cornors of the cutout are rounded to 5/8" radius to prevent cracking. I left a 1" rim around the cutout. The window was glued back into the door with 100% silicone caulk.
The movable window is 3mm (.118) acrylic from Menards. There's an aluminum trim strip on the front edge made from ordinary aluminum flashing material (1" x 12") hand bent and glued on with CA (superglue). I had to curve the movable window to match the curve in the old window...300F for 5 minutes in the wifes oven then let it cool ON the old window and it assumes the exact same shape, near perfect fit.
The handle is .020 brass sheet bent 90 degrees and attached with #6 button head screws. The window slides easiest if the handle is mounted below the center of the window.
The self adhesive felt (about 10' needed) came from aircraft spruce in 1 1/2" width ...I cut it lengthwise to make 3/4" strips. Then lengthwise again to make a 3/8" strip for behind the aluminum trim piece.
After many elaborate plans, curved tracks, latches, seals and much input from forum folks (Thanks Joel), in the end I decided to keep it simple. I cut a big hole in the original one piece window, added some felt strips, and fitted a movable window over the hole. Works great.
The hole is the old window is at the Lees elbow position (aft) roughly 12X12. The cornors of the cutout are rounded to 5/8" radius to prevent cracking. I left a 1" rim around the cutout. The window was glued back into the door with 100% silicone caulk.
The movable window is 3mm (.118) acrylic from Menards. There's an aluminum trim strip on the front edge made from ordinary aluminum flashing material (1" x 12") hand bent and glued on with CA (superglue). I had to curve the movable window to match the curve in the old window...300F for 5 minutes in the wifes oven then let it cool ON the old window and it assumes the exact same shape, near perfect fit.
The handle is .020 brass sheet bent 90 degrees and attached with #6 button head screws. The window slides easiest if the handle is mounted below the center of the window.
The self adhesive felt (about 10' needed) came from aircraft spruce in 1 1/2" width ...I cut it lengthwise to make 3/4" strips. Then lengthwise again to make a 3/8" strip for behind the aluminum trim piece.
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