- The first thing we do is remove the two side vent decorative vent
covers. These are attached via 3 screws which can be removed from the
underside of the hood (fig 4). With the screws removed the vent covers
slid inwards towards the center of the car and then pop out. Do
not try and pull them directly up. Slide them inwards first. Next we
need to tape the front and back of the glass to prevent glass fragments
from getting into the engine area and all over the car (fig 6 & 7).
Cover the engine area anyway to trap stray pieces of glass. Ware
goggles! We next need a special tool used by auto glass shops t
cut the urethane seal between the glass and frame of the car. This tool
can be found on the web and is shown in figures 8 & 9. It is just a
right angle blade with a handle to pull it along. Force the blade under
the glass/urethane area and pull the blade all around the edge of the
broken glass window. The urethane cuts surprisingly easily. Then
carefully remove the dislodged glass window. Remove and cleanup any
glass fragments. Use a vacuum to clean up everything. Remember any loose
glass will scratch the paint surface of the car if rubbed on it.
Figure 10 shows the hood with the glass removed.
Next we need a sheet of polycarbonate 28 and 7/8" X 25 and 1/8"
about the thickness of the glass you removed. This material comes
under many brand names. There are all kinds of variations as well. Such
as UV resistant material, scratch resistant etc etc. I will try just the
"regular" stuff for now! I should point out that the front and
rear edges are slightly curved, so the rectangular sheet need to be
filed along these two edges to have a good fit. Before we install
the glass we need to black paint a border around the edges of on each
side. Carefully cut the paper backing to exactly the black area used in
the OEM glass cover (fig 11). Regular indoor/outdoor spray paint
is fine. I first used the auto high temperature black spray paint. It
did not stick well to the plastic. When done the plastic sheet should
look like that shown in fig 12.
I then trimmed the black urethane all around the window border area
of the hood making sure it was even all around and carefully placed the
polycarbonate sheet into position. The surface is slightly curved
horizontally on the hood. To insure a solid fit I drilled 4 small holes
in the corners of the sheet and into the engine hood. (These 4 holes are
in an area normally covered by the OEM glass black painted area and so
will normally not be seem if I later decide to go back to the OEM
glass). I pressed in 4 plastic auto carpet studs to retain the
plastic curvature (fig 13 & 14).
The hardest part of the whole operation turned out to be getting back
the 3 retaining screws fort the vent covers. They are at a strange angle
and kept falling down into the base of the hood. The solution was to put
a drop of glue on each nut head to hold it to the Torex socket and then
with a socket extension position and screw the nut in place (fig 15).
When tight the socket can be easily pulled off. Figure 16 shows
the finished product. It is almost impossible tell it is not glass
unless you actually tap on it with your fingers.
So far I have driven 200 miles with this polycarbonate cover. No
problem with heat or cracking. I have hear that some Ferrari car covers
are in fact Polycarbonate. Time will tell. I am keeping an open mind for