try acrylic!
i just made lenses for my new headlights, i found alot of good info while researching which plastics to use.
I ended up using acrylic (plexiglass) over lexan. If you are bending or forming the panel with heat from a heat gun, you will most likely bubble the lexan, but acrylic is much less prone to bubbling under high heat. Lexan is really strong, but unless your going to hit your window with rocks (in which case glass would brake too), then id go with acrylic (which is still 20x stronger than glass). Acrylic will not scratch as easily as lexan, which scratches very easily. Lexan is also not as clear as acrylic, which is 8 times clearer than glass!
pick up some acrylic and practice bending with a heat gun, a whole windows is gonna take you allll day but after some practice you will find it is possible to make some nice clean bends. just use a template underneat the sheet, heat it up enough and all the sudden it will fall onto your template (do not push it down, you will leave marks). then let it cool and your done! practice makes perfect.
oh, another tip, any swirl marks or scratches you get in your panel, use toothpaste on it with a cloth, takes em right out.
[This message has been edited by rmphoto (edited 06-18-2006).]
