Installation Instructions
Please read the following helpful tips before installing your new Clear 1 windows.
Polycarbonate (Lexan) Window Replacement
1. Remove your existing window and set aside. Leaving the protective film on your new window, test fit in opening and mark any areas needing trimming. You may also use your existing window as a template to mark areas needing trimming.
2. Trim as necessary using a jigsaw or router, finish sand for clean edge.
See back for cutting and finish sanding tips.
3. Drill mounting holes by laying existing window over Clear 1 window, we recommend clamping the windows together in order to keep holes aligned. Be sure to countersink holes when finished. Test fit again.
4. Border Painting, you may want to add a black trim to your Clear 1 window to hide all of the installation hardware.
See back for painting tips.
5. Installation, after paint has cured you are ready to install. Peel back inside masking material approximately 4” around entire edge. We suggest that you leave the outside masking on during installation. Begin bolting your window in place starting in the center top and bottom working your way to the edge. We suggest that you snugly install nuts and bolts every 3-4 holes to keep the window aligned properly, once all bolts are in place you can do all final tightening. Do not over tighten bolts, the window should be firmly attached but not concaved around bolt area.
6. Remove all masking and clean windows using Plexus cleaner or mild soap and water mixture.
See back for cleaning tips.
7. Apply date sticker to the inside of the window (supplied with these instructions) for warranty and contingency purposes.
Replacing Glass with Clear 1 Windows - Existing trim application
1. Find a flat surface with enough room to accommodate the entire surface of your existing glass window. Remove window and place face up on table. Leaving the protective film on your new window, lay your new Clear 1 window on top of the glass and clamp down following the contour of the glass. Flip over and trace the outline using a permanent marker.
2. Trim as necessary using a jigsaw or router, finish sand for clean edge.
See back for cutting and finish sanding tips.
3. Border Paint, you may want to add a black trim to your Clear 1 window to provide a stock or factory look.
See back for painting tips.
4. Installation, after paint has cured you are ready to install. Peel back masking material approximately 4”. We suggest that you leave the masking in place during installation. Apply trim and test fit.
5. Apply adhesive and set window in place. The use of adhesive alone is not recommended for racing applications.
6. Remove all masking and clean windows using Plexus cleaner.
See back for cleaning tips.
7. Apply date sticker to the inside of the window (supplied with these instructions) for warranty and contingency purposes.
Replacing Glass with Clear 1 Windows - Bolt on application
1. Find a flat surface with enough room to accommodate the entire surface of your existing window. Remove window and place face up on table. Remove any gasketing material or hardware left on window frame. Clean surface and prep for new solid gasket and adhesive material.
2. Leaving the protective film on your new window, lay your new Clear 1 window on top of the glass and clamp down following the contour of the glass. Flip over and trace the outline using a permanent marker. It may be necessary to add up to ½” to allow the new window to fit flush with body without trim, we recommend the use of a chipboard template in addition to the stock window to ensure a proper fit.
3. Trim as necessary using a jigsaw or router, finish sand for clean edge.
See back for cutting and finish sanding tips.
4. Border Paint, you may want to add a black trim to your Clear 1 window to hide the installation hardware.
See back for painting tips.
5. Install Clear 1 solid rubber gasket material with the supplied adhesive. Allow to set for a minimum of 1 hour before continuing with installation.
6. Installation, after paint and adhesive has cured you are ready to install. Peel back masking material approximately 4” around entire inside edge, leave the outside masking in place. Mark holes approximately every 4” on paper masking. With window in place, starting in the center drill marked holes and countersink. We suggest that you snugly install nuts and bolts every 3-4 holes to keep the window aligned properly, once all bolts are in place you can do all final tightening. Do not over tighten bolts, the window should be firmly attached but not concaved around bolt area.
7. Remove all masking and clean windows using Plexus cleaner.
See back for cleaning tips.
8. Apply date sticker to the inside of the window, supplied with these instructions, for warranty and contingency purposes.
Cutting, Sanding and Drilling Recommendations:
Band saw - Cut at 2500-3000 ft/min using an 8-12 tooth per inch blade.
Circular saw - Cut at 6000-8000 ft/min using a 3-5 tooth per inch blade.
Router - A 1 hp router with a straight 2-3 blade carbide tipped steel bit.
Sanding - Use a standard palm sander with 180 grit paper.
Drill - Preferred at 1750 rpm using standard steel bit.
Border Painting
Peel back the masking material approximately 3” around entire inside surface, holding the masking away from the window and using a razor blade or scissors trim this material off cutting the masking only and not the material below.
You are now ready to layout your border. Using 3M Super 88 tape or equivalent layout the inside edge of your border (1.5” from edge of window is standard). For radius corners it is best to cut in advance of application or w ith an exacto knife gently cut the masking material and remove. Once you have the masking in place be sure to fill any gaps left between your border layout and the masking earlier removed.
Border painting your Clear 1 windows requires that all hardcoating material be removed for the paint to adhere properly. This can be done with a palm sander and 180 grit paper. The edge should be dull when wiped with a damp cloth; any areas that are not should be re-sanded.
Using Clear 1 Border Paint or lacquer based matte finish paint apply as you would with normal spray paint, allow to dry and repeat.
Cleaning and care of your new Clear 1 Window
Maintaining your new Clear 1 window can be achieved with a few simple do's and don'ts. First lightly wipe your window with a damp cloth to remove any coarse debris. Second, using Plexus or a mild soap and water mixture (Joy or Palmolive) and with a soft cloth gently clean the window. Once this has dried you can then polish with a clean soft cloth. Do not use Windex or any type of abrasive cleaners, to avoid streaking do not clean in direct sunlight.
Date of Manufacture Sticker
We have included a date of manufacture sticker to these instructions for your use. This sticker should be placed in an area that will not disrupt your vision in any way; on a front window the lower passenger corner works best. We guarantee or products against fading, cracking or yellowing for a period of 5 years. The date sticker must be applied for any warranty claims or contingency payouts.
Disclaimer
Clear 1 windows are intended for racing or off road use applications only. These products are not yet D.O.T. approved for street use and are illegal on U.S. Highways. Clear 1 LLC assumes no liability or responsibility of these products if used illegally.
For assistance please call us at 1-(866)-7CLEAR1, we will be glad to help.
