Yep, you heard me Right. $20ish to replace your rear window.
Now if you have the money for a new top, this thread is not for you. This is for the frugal person who doesn't want to throw away a small fortune on a new top. My top was in perfect shape and being a Cali car my window was sun beaten and shot. I rarely ever drive my car in the rain or in cold weather. My top is down 95% of the time it is driven.
Preface: I am 6'3" , 245lbs and have zero sewing experience. So if your a nimble little fellar, you should have no problem getting in and out of the car. I am not and I paid the price the next days as I was sore. This job wasn't that hard, just monotonously painful.... Put a stitch in from the outside , go in the car and put the stitch back out..... repeat like 500 times!
Difficulty level: Removal=1, Sewing in new=4.5 out of 10
The top and sides were about a "5" due to me being 6'3" and having to get in and out of the car for each stitch. The bottom was easier and rated a "3.5"
TOOLS: Got most of the stuff at Joann fabric and craft store.
1.) Vinyl Plastic 20gauge $7.99 1yd(enough for 2 windows) Get thicker if you can!!
2.) heavy waxed carpet thread(nylon was too weak) $4
3.) Thimble $1.99(had it)
4.) 10 #2 needle $2.99(had it)
5.) Razor blade
6.) Coleman Seam sealer $3.00 (walmarts)
7.) 3m outdoor black carpet tape(waterproof double sided)
Procedure: "Removal" 15 minutes or less
Hint: Remove your belt buckle!! Better yet wear sweat pants or you will scratch the hell out of your baby!!(I didn't scratch mine, but have seen it done by the newbies at my dealership)
1.) From the outside, use razor blade between plastic and vinyl top. Mine glided through with no problem. Window comes right out.
2.) Remove existing thread. I used the dull side of the razor and just scrape the thread right out of the holes. Go from inside to the outside and use your free thumb under to push it up as you scrape. I tried a thread remover, but the blade worked like a charm. Took about 8 minutes. I had no oops or damage of any kind.
3.) Keep and use old window as template for new. Clean off any debri or old canvas
4.) Edited: Make the window larger than the old one. at least 2" around larger.
5.) Using utility scissors, cut out the new window and you are almost ready for the install. Be careful not to scratch it.
6.) Edited: I am using Black gorilla duct tape on both sides of the window to add support and keep the stitches from pulling through.(see pics).
Removal Pics:
New window:
Notes: don't cut your finger nails as you will need them for removing the old thread. I would have preferred a thicker plastic, but I have to deal with what I have. I need to figure out a few things before installing it. Like what to use to keep threads water proof.
UPDATE: I tested a left over piece and the blow dryer had no effect on shrinking the vinyl. I hoped to get out some of the imperfections. Don't get me wrong as the vinyl isn't that bad, i just hoped to get it better. I would rate it 7.5 out of 10 as to the original "new" window.
*if you would rather remove the whole canvas top here is a link, but be warned you might as well buy a new top if you go this route as it isn't easy
http://images.wikia.com/boxster/images/e/eb/DIY_Boxster_Conv_Top_Canvas_R_R.pdf
Removing the top as a whole has been suggested as an alternative to just the canvass.
Install New Window:
This is the hardest and most time consuming process.
You will need at least 10 #2 needles or tapestry needles(work a little better as they are shorter), a roll of 3m outdoor double sided carpet tape in black, and needle nose pliers. I am doing this in 4 parts. top, sides(2) and bottom. I am saving the best for last(actually bottom is the easiest).
1.) Ok by now you should have your window cut out and taped.
2.) "Dry" fit you new window into your hole and mark(not on window) where the center is. If you have trouble with this then skip to step 3
3.) Use the Double sided 3m outdoor carpet tape, 3" strips, on the top center and both top corners. This will help you center it.
4.) Once centered, put one or two stitches in the center top (use the existing holes, if you have trouble seeing them use a flashlight from underneath),use 3 foot length of string and leave the needle hanging as you will use it in a few minutes. I used 2 needles to start the first stitch from the out side and tied them on the insed and removed 1 of the needles.
5.) Now put a longer dbl sided sticky tape across the length of the entire top between the canvass and the glass(put on canvass first). This will act as a good water seal and to help you sew it in.
6.)Sew in a stitch in each corner the same as the middle, leaving a 3 foot length of string hanging. I sewed both towards the middle. (you can do it any way you want).
7.) Now you should have 3 stitches with 3' pieces of string.
8.) This step is a huge time saver. as the pic below shows, pre "poke" your holes. (this helps the needle goes through easier and more uniformly and you can see the hole in the black tape on the inside and will give you a great uniform look). I found it easiest to use a pair of needle nosed pliers and grasp the needle in the middle to poke the holes, other wise you sill break needles left and right.
9.)Start sewing!!
10.) Less than 2 hours later, I almost have the hole upper half done in about.
Finale:
11.)Last part (bottom) was easier than I thought. In fact it was the easiest part. I put the bottom of the top up and was able to sew without going in and out of the car. Took about an hour.
12.) I plan to cover the inside stiches with Gorilla duct tape as it will act as water proofing barrier and keep the stiches in place. I plan to use seam sealer on the outside stichtes
13.) color thread black let dry an hour(black sharpie) and then apply seam seal per its directions.
Final Picture:
Just washed the car for the first time and it rained(of course). I experienced no water leakage at all!!
Thoughts: I like it. It was a pain, but it definately save me money. It looks good, but not great, but I knew that going in. Money is tight and I needed a cheap fix that I wasn't embarrassed to be seen in.
After thoughts:
I colored the threads black with a permanent sharpie and they almost disapeered. I used heavy, waxed carpet thread for a couple reasons; first= I had it, second= it will not break!! Your best bet is to get the color that matches your top. I tried other threads but they all easily broke between my fingers. I would highly suggest using the 3m double sided sticky "outdoor tape". It is a must!!
I left the car in the sun so the tape and window warmed up. This made it seal better and was easier to push the needle through. I should have it done later tomorrow moring. It should take 2 to 4 hours to sew it in.
Good luck and if you have half a Saturday it is well worth the time and effort.
Let me know if you need any help or get stuck.