Custom Windows


Making Custom Windows by Sinisa Pismestrovic

If you want to restore or customize a car and have no possibility to get original replacement windows, here is a method to make custom windows of your own using a blister pack clear plastic blister. It’s cheap (yes, the custom blister pack windows are thinner than original plastic windows, but it adds to the realism) but with a little practice you will create realistic windows on your own giving the otherwise useless blister pack a new use. [This method is also good if you have only colored glass available and want to add interior details]. Really any blister pack will do from most any diecast provided it has some thickness to it and is not flimsy. First, make a template of the window. Take a sheet of paper and a pencil, go smoothly with the pencil shading over the paper. The edges of the window frame will show on the paper and provide a template of the area to be used. This is the same method often used by coin collectors when the engraved symbols and numbers are not easily visible. w1

The result, on the paper, should have a similar shape to the window frame on the car. Cut out the window shape.


Now take the blister pack and put the window shaped template paper on it. Trace the template with a water resistant marker (take a fine one, because the fat ones will go through the paper) and draw lines along and around the paper edges. You will get the same window frame shape outlines on the blister plastic.


Cut out the plastic along the lines keeping in mind that you will need some extra space where you will glue the window to the body casting. Allow for an extra 1/8th inch which can be adjusted when fitting. Cutting can be done with knife or scissors.


This sample shows some flash space that was left on the bottom of the window where the main glue area will hold the window to the base.


Now check how the window fits to the body. First attempts should be made without glue, to adjust the window perfectly to the bodies window frame. Trim an excess flash that may have been left when cutting the template. Be sure to glue carefully and not leave fingerprints on the see-through pieces of the window. Some glues will also fog the clear plastic.


On the rear window the same method was used, but additionally the window had to be folded to fit the window frame. Fine cuts/scoring was made along the fold lines to make the plastic bend easier, In the bottom-middle of the rear window you can see the area where the window was glued to the body. The rear window was painted with black enamel along its frames to create a realistic impression. You can draw the black frames with a black marker pen as well.


This picture shows the side windows also have a rather large area residing behind the roof pillar on the inside of the casting. This is where the glue is being applied.


The final result:


I hope I explain you this method clearly and gave you some inspiration. I wish you all the best and a lot of fun with customizing! Sini

Thanks Sini!! 

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