Great thread. It's funny - I've been sitting on some pics and my experiences with this for a while. Kept meaning to write it up for the site but haven't gotten to it.

Material: I used a tinted lexan-like material called Makrolon that actually has a hard coating for better UV and scratch resistance. 2 years in, they still look great and feel safer than glass.

I used the old portlights as templates. The Makrolon has a protective film on it. To get the best adhesion, I also used the Sikaflex that requires a primer (209D). So, trimmed off a small frame that I then brushed with primer, primed it, and then applied the compatible Sikaflex caulk (295).

Later, I came back with some Sikaflex 291-White to seal the inside to have a clean finish.

Here are a couple pics...





This is a very easy, low cost project that is well worth it!
- Jeff

Great Job! I'll be working on mine soon. What do you think of using Lexan material?

Consider the fact that on some auto racing circuits, the racers prefer to use lexan instead of glass for windshields.
While I already have one scratch in one new Polycarbonate [lexan] window, done by impact with jaw of spin pole, all it is is a scratch.

looking at my old set of windows ... there were no scratches just 27 years of cleaning the outside surface with all the wrong chemicals. The insides were fine.