Acrylic material is more scratch resistant but more brittle than
Polycarbonate (PC). LEXAN is GE's trade name for PC.  PC is used by many
auto manufacturers as a replacement material for headlight assemblies.  PC
is also used as the material of choice in the thick plates of bullet proof
"glass".  

With PC you have a durable and tough material with good impact resistance
and a much better working temperature range. Its impact resistance is much
higher than Acrylic at lower temps and if you are doing any winter driving
this is a good point to consider.  However it is harder to work with if you
don't have the correct tools.  PC's scratch resistance is not as good as
Acrylic's but with a hard coating applied it can begin to get close.  What
you pay for in those aftermarket parts may end up lasting you a great deal
longer for your efforts.  You are paying for their investment in tooling to
make the product with the right material.

Cheers,
C

-----Original Message-----
From: robertmstewart [mailto:robertmstewart@MAC.COM]
Sent: Friday, September 19, 2003 7:58 AM
To: vanagon@GERRY.VANAGON.COM
Subject: Re: Headlight Crack Protection

Happy Friday to all,

2 weeks ago I had a rock or object crack my front right small headlight
glass. This got me thinking about ways to protect it. I know they make Lexan
covers but I figured that for the same $50 dollars I could just go to the
plastic store and pickup some thick clear acrylic sheets, cut it to size to
cover both the low and high beam glass.

I am not sure how to adhere it to the glass, I guess I can figure someway to
adhere it to the body grill. Maybe Clear Silicon, or a possibly 2 mounting
screws. I am open to ideas. I just can�t see purchasing those lexan covers
when I can make it myself. Anyone see any draw backs to this idea?

Anyone know how those Lexan Lens covers adhere to the Glass?

Thanks,

Robert
NYC
89 Carat Auto