[BikePump]

In order to get easy access to adjust my rear dampers on the 996 I am going to fabricate lexan rear-quarter windows to replace the glass ones. I plan on using quarter turn fasteners like dzus to attach the windows to the body. My initial thought is to use three fasteners in the same general locations as the factory glass attachment bolts existed. Any advice or potential gotchas I should know about?

[Vicegrip]

poly-carbonate is more "bendy" than glass. How thick is the poly-carbonate going to be?

1/4 turn might not be needed unless you intend to remove and replace often. Regular threaded flush bolts are real easy to set up.

[Trak Ratt]

Sounds good, though I like probably most other thought the stock 1/4 windows were held in place by the rubber gasket/seal?? A pic or diagram might help.

[HoodPin]

dzus fasteners are great, but have to be installed precisely. and you don't want to attach too tightly, which might cause the lexan to crack. The key is getting the anchor wire at the right depth, so that the fastener twists onto it properly. Very doable, but be precise. Plus, you want to be careful when attaching the fasteners to the lexan, to avoid cracks at those spots.

Alternatively, you could also attach some flat tabs to the underside, and tap some threaded holes into the tabs, and use some regular bolts to attach (x2 what VG posted before me). Cheaper than dzus, and easier to replace when you lose one in the tall grass.

[Ryan]

All great answers, but you might want to reconsider. Not Allowed in Stock class

[BikePump]

the lexan we bought is .12" (3mm) and is pretty tough stuff. I used the .090 for the removable door windows and they have stood up to abuse and have not experienced any issue where i drilled and attached handles onto them.

The reason i want the 1/4 is that I want to be able to remove the window as needed to adjust the suspension. the standard window bolts and the top of the dampers are extremely hard to reach. I am trying to make it a "no brainer" to take off.

The stock windows do have a rubber seal as well and after experimenting with the glass (already removed) its easy to pop in under the seal.

[BikePump]

Originally Posted by Ryan

All great answers, but you might want to reconsider. Not Allowed in Stock class

well that could change everything!

[John Clay]

read the rules, who wooda thunk?

[BikePump]

Originally Posted by John Clay

read the rules, who wooda thunk?

there is always subtlety there so I did email to get clarification. if that is the case then I will have to come up with some other quick release approach for the stock glass....<sigh>

[HoodPin]

Originally Posted by BikePump

there is always subtlety there so I did email to get clarification. if that is the case then I will have to come up with some other quick release approach for the stock glass....<sigh>

You could attach some tabs to the exterior body work around the glass. Drill some holes in the sheetmetal, and then install a couple of threadserts, so you can attach the tabs with bolts instead of sheetmetal screws. This is what many do to attach their lexan windshields, or sunroof panels.