Rear Window Guard

[Moggs]

Hi All,

Have just spent a few hours this afternoon making up some rear window guards to keep any errant stones from ruining future holidays. I thought I'd post some info up here as it might assist someone else considering doing something similar.

Although the Tambo has a an excellent stone guard I wanted to use something to cover the back windows. Tambo stone guard:



I looked around at the commercially available rear window products and thought they were a bit expensive so set about making my own.

In the end I bought two sheets of 900 x 600mm 3mm polycarbonate for $69 from Bunnings along with some Velcro Brand adhesive velcro dots ($7.95 for a 40 set pack) and some clear rubber adhesive buttons ($3.95 for an 18 pack). All up cost to make the window savers was therefore $80.90.

I used a butchers paper template to get the shape right and then cut it out with the jigsaw set on low speed using an offset tooth aluminium / plastics blade which I already had. The vertical and horizontal cuts that terminate in a drilled hole (done with a blunt drill bit at slow speed) allow the polycarbonate to bend with the curve of the window and the clear rubber buttons keep it off the glass. The hook velcro dots stay on the vehicle - which is ok as they don't interfere with anything (wiper just slides over them)

All in all very happy with the result! Would highly recommend making your own - it was dead easy! A couple of tips I picked up from researching the web prior to starting last night:

- Use masking tape top and bottom of the polycarbonate prior to cutting.
- Clamp the sheet close to the cut for the full length prior to cutting.
- Make sure the jigsaw is on low speed to prevent shattering and melting
- Use the 'Velcro' or '3M' brand velcro dots as they have better adhesion in the heat than the cheaper brands
- Use a blunt drill bit on low speed to terminate the horizontal and vertical cuts
- Remove the window saver when not towing as it may loose adhesion if sitting in the summer sun - no problem, just toss them under the camper when arrived
- The Velcro Brand dots come in a 40 set, so have some left over to carry as spare in the vehicle

Hopefully some others will find this useful.

A few photos of the finished product:

[earvin]

Nice job Moggs Very professional How do you think the velcro will hold up to corrugations and the like?

[Moggs]

Thanks earvin. I am pretty sure it will hold up ok offroad. Each sheet is held on by 16 velcro spots and the vertical / horizontal cuts ensure there is no leverage on them. The sheets at 3mm are light so there should not be any stress on the velcro. The sheets stick on very firm and you really have to pry each velcro spot undone one by one to get it off. I will carry spare velcro spots in the kit now, hopefully they will not be needed.

[earvin]

Thats awesome Moggs. Like i said top effort Looks better than having a real estate for sale sign in your window

[Shemdaph]

Man u inspire me. I m going to make some. How is the rear vision through the polycarb?

My only problem is that I m useless with a jig saw. I rarely get a straight line.

[Moggs]

LOL!, I can't cut straight with a jigsaw either, but luckily the cuts to match the Patrol rear windows are curved.

Vision is fine, no distortion. It will be inetersting to see if it scratches up or hazes. Will just need to be careful cleaning it I reckon.

[Johnny Trackabout]

Great job Moggs......where do I place my order?

[Bushman]

Great stuff Moggs. 

Need to do one for the Pathie, would you recommend making it 2 piece or 1.

[GU Rich]

Great job there Moggs!! great detailed info on the process of your design. Just one question mate how much clearance is there between the glass and the window saver? And would there be much chance of the glass scratching if dirt ect went between?  I guess thats 2 questions!!
Cheers Rich

[Moggs]

Great stuff Moggs. 

Need to do one for the Pathie, would you recommend making it 2 piece or 1.

Hi Michael,

I reckon you should do 1 piece for the Pathy glass - no real reason to do two that I can think of. Hope all is well.

[Moggs]

Great job there Moggs!! great detailed info on the process of your design. Just one question mate how much clearance is there between the glass and the window saver? And would there be much chance of the glass scrathing if dirt ect went between?  I guess thats 2 questions!!
Cheers Rich

Hi Rich, Hopefully the process I used can help someone else make their own. There is at least 5mm clearance between the polycarbonate and the glass all over. The clear rubber buttons that are at the end of each vertical and horizontal cut that terminates in the drilled holes ensure it doesn't touch in the center of the sheet due to the curve of the glass. The velcro dots also hold the sides off about 5mm. I don't think there is anyway that dirt would cause issues if it went between. With the gap I am sure you could easily clear any dust / dirt out with the hose if needed.

[Moggs]

Great job Moggs......where do I place my order?

lol! Sure $250 a pop sound cool?? .

BTW, I am happy to send a butchers paper template of the Patrol rear savers to any fellow Patrol owners if they want.

[cruza driver]

Mate very impressive job you have done  looks good

[GU Rich]

Cool Moggs thanks!! i was just wondering..

[Troyk]

Moggs, Nice job.

How much clearance between the guard and the window?