How to make ANY curved windshield using ACRYLIC THERMOFORMING method - Part 1: Making a Metal Buck

Today we're going to show how to make your own windshield - whatever shape and size. Crazy, right? The biggest issue when chopping a roof is the glass situation. We really feel that this method we're about to show will change the game for all customizers who encounter the same issue 🔥
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#badchad #acrylicthermoforming #plexiglas #plexiglass #formingplexiglas #customcars #custom #customcar #cars #car #customizing #curvedwindshield #makingabuck #buck

[@Barnacules]

Just watched your Premiere today, you're awesome @bad chad!

[@tonymosca6591]

These “how to” segments are the best especially the way Chad does the ,low cost and effective.

[@kyrompstomp]

Been around a long time. Never seen a Man so eager to solve a problem, so all people can enjoy their DREAMS at your level. I am 87 years old old body man. I am willing to try my best to try my hand at my wants and desires. THANKS CHAD. MEL AND GINGER.

[@MongoLloyd74]

I love your process and how you sort of figure things out as you go. I'm ADHD and I find myself explaining to people why I think out loud so much while I'm working on something. It seems to be the only way I can focus on what I'm trying to figure out without thinking about ten other things at the same time! I tend to overthink myself into a state of motivational paralysis. Nothing gets done! I'm certainly not implying you have some sort of mental condition, I'm just saying it's inspiring to see that someone who's process is similar to mine can be so accomplished at what they do. Thank you for the video.

[@INFIDEL82AA]

You're not alone on that front, Mongo. Motivational Paralysis runs rampant in my garage. In fact, sometimes it's the ONLY thing happening.

[@badcommentbot8349]

Pedo dog

[@michaelm.1927]

Watching with my son,he enjoys how you educate without over complicating it. Thanks for hightening is interest.

[@dorothywithers4690]

Love watching your KZbin videos Chad and Jolene.

[@mikehalm164]

Never heard of clear vinyl wrap, but it sounds perfect for this and other disiplines. My buddies who build airplanes (homebuilts) will love this. Even the kitbuilders who receive preformed windscreens could wrap and protect these parts. Over time, plexiglass grazes and fades and considerable effort is spent polishing so one can see where he/she is going. Excellent video!

[@davegeoffroy7606]

Hey Chad, I have to say I love your work and creativity! As a car guy I seriously enjoy watching your show! Thank you for all you do for all of us car enthusiasts and even more so for giving us creative ideas on how to make and build things! You’re not afraid to try anything and I have a lot of respect for that kind of attitude. Here’s to you and Jolene! Keep up the great work!

[@scottimc72]

I can't believe how good it looks with the bits of cardboard taped to the back window. Great visual. Thanks for a great video guys.

[@alexjohnson9328]

A true fabricator that breaks it down step by step so anyone can make their dreams come true. Chad is the master of problem solving.

[@stallion1369]

Whoop Whoop! Great job Chaddy.

[@garybarry4446]

So love watching your creative mind at work building cars

[@JamesWalker-s9t]

I really like the idea of clear vinyl wrap to protect the acrylic windshield. Thanks for sharing your ideas and work. Genius at play!

[@Saltbox97]

I take it back. Last vid I said I would leave window in but now that you walked through an explanation of what you like less about the current window I can totally see what you’re saying. I was also lazy yesterday and it must have been impacting my judgement so I went for the easy-peasy. Btw- it was fantabulous to see and talk to you and Jolene yesterday at Princess Auto!

[@adventuresinmusic2487]

The rear window from the side looks splendid. My brother works in a glass shop. He turned me on to non-scratch Lexan. I've used it in construction and on race cars. Way better than Plexi. And... you can bend it in a sheet metal brake.

[@wht240sxka]

Don’t you mean pexi gas. Hahaha

[@mikeburk3840]

I use the lexan on yachts and rv, dune buggy. I swear by lexan. It's very tough.

[@jaywatts333]

i 1st saw you 2 1/2 yrs ago after they cut out 1/3 of my guts due to cancer. in recovery i watched you on cable tv everyday. i forgot about you til i saw japhands the other night. so i subscribed. love the window molding. great idea.... lol from Huckabay, Tx.

[@stevenvilardi8626]

I’m impressed. We have a mint low mileage 1991 Nissan that our parents bought new. My sister has it as a second car. One day she left it outside in the high rise outside lot. She theorizes that someone dropped something off one of the many balconies in her building. Whatever it was the rear window shattered. She called a number of glass places and they all claim a Nissan Stanza window is not available anymore unless salvaged from a junk car. Apparently none of the Nissans are junk. I have not been able to find a rear glass let alone get it out without breaking it. I may just try your method or similar to fill that void in the rear of the car. Thanks for the great videos. Ps plexiglass is very expensive a places like Ace, Home Depot and Lowes. Ps2 will SAR plexiglass resist windshield wiper scratches.

[@alexanderscott3647]

I'm not sure if it is still practiced or not but window customizers used to use something on the order of an autoclave and a sand box with the shape of the customers window imprinted in the sand of the sandbox then rolled into the autoclave to take shape. I've also seen this done on the program of "How it's made". Two sheets of glass were cut to match one another then both sandwiched together, after baking and curing the safety vinyl was put in-between , then baked again until vinyl is clear. good luck. hope the best for you from one body man to another.

[@louisarsenault1243]

Great metal work on the front windshield Chad, can't believe how quick you got it done. Love watching you guys work. Thanks

[@INFIDEL82AA]

He just gets in there and knocks it out! That quickly… task at hand, solution/process, work it until complete. The BadChad way

[@jimcoplan9502]

More window work today. Chad is trying some ideas and working with plexiglass. More to learn. Thanks Chad and Jolene for the great lessons.

[@jesshamilton576]

Chad, sorry this so late just ran across this channel. Your excitement at overcoming your insecurities is addictive. Personal wins in your own mind are the greatest satisfaction I believe exist. I am so much reminded of myself watching you on KZbin trying out whatever grows in your imagination! I don't build the same type of projects as you but the procedures are the same for finding what you love to do. I have watched you on Discovery but there's too much added drama for my taste on that show. Your wonderful partner knows you so well it's a real pleasure to know how much you respect and appreciate her and her instinctive camera work is exceptional too. I hope you find great success with this medium. Keep at please!

[@MattyB3D]

It does look better. The VISION is everything!

[@scottcobb4966]

Your energy is palatable! Love it when you can witness inspiration happening. Always enjoy the ride you take us on! Keep up the great work too!

[@CAROLDDISCOVER-2025]

When it comes to creativity there are no hard-and-fast rules only general theories and principles. Even those are meant to the work with and applied. This is what you do so well. I could say you think outside the box but that really wouldn't be quite as descriptive and accurate of a description of your talent and just simply going after it!

[@dansautorestoration]

Are the safety regulations different in Nova Scotia? I spent about 20yrs in the auto glass business, and AS1 grade laminated glass was all you could use for windshields and had to be stamped marking it as such. The stamp is on either lower corners or the bottom centre of the window. Door and quarter glass, if flat could be made of AS2, and back window could be AS3. The grade is based on the thickness of the lamination between glass layers. Any vehicles imported from Europe that originally used tempered glass for windshields had to have them changed over to a AS1 laminated windshield before it could be legally driven on the highway. And yes, they used tempered glass for windshields in some areas over seas.

[@i8ntnuts]

I don’t think the goal is to build roadworthy cars. This is more about teaching his way of fabrication that anybody could do.

[@kevinjohn5410]

You are for sure a idea's man, an artist and know how to solve problem's and let nothing stop you from achieving your end goal ... Like the way that you treat Jolene and work as a team ... luvin your show from Whyalla Australia

[@donthompson9300]

Love the new look of the back window. Thought I liked the way it looked, until I saw the change today. Pure genius!!!!!!!! Looking forward to see what tomorrow brings.

[@i8ntnuts]

I haven’t watch the whole show yet but I love the rendition of his first side profile. It doesn’t look custom but it does follow the lines of his little molding piece.

[@darylnicklen242]

Wow Chad first time here and now a subscriber. I'm 62 out of Australia. I'm hooked I'm just want to see your plan all work out glad your sharing your plans and showing how it's done. Never to old to learn. Thanks..

[@MMFH_LIFE]

I’m excited about the vinyl wrap idea! You weren’t joking about changing chopping. That opens a lot of options for the end problem of chopping! Awesome thinking!! Have a good night.

[@bosnuts7058]

Love that Bad Brad does not settle for good enough!

[@garyfairbrother5532]

Great solution! The back window does indeed look 100% better. That will simplify windshield making until “Scotty’s” formula for transparent aluminum becomes available. Good one Chad! Can’t wait to see the finished product.

[@footballseasonishere1314]

I still don't understand why there is still only 117k subs. You guy's have some of the best videos on the web. Just remember " it's all about perspective, yes it is". Another useful, educational video.

[@donaldgrant8433]

I must tell you. Doing what you do has always been a passion of mine.now that i have the time im going to do it. I cant stop watching you and feel I've learned so much. The windshield video is at the top

[@carlosvoncarlos2626]

Enjoyable video. Nice change on the back window.

[@michaelboulter8706]

A perfect solution to a common problem when customising cars. Well done!

[@rickdarr5323]

Best channel on KZbin... thanks for all that free knowledge Chad.. can't wait to see how the windows turn out.

[@i8ntnuts]

Definitely the most entertaining KZbin channel around. I never get tired of watching him and the ideas he comes up with

[@rickdarr5323]

@@i8ntnuts you do get some good ideas 💡

[@jimmyattard1446]

Glad you decided on smoothing out the silhouette of Elvis with the swept back rear window. This is going to be fun viewing wether your idea works or not. Thanks for the good camera work Jolene

[@elavationchild]

Chad keep up the positive attitude and hard work ethic. I hope all the kids are watching.

[@awh3399]

I know I’m repeating myself, but over and over again Chad shows how fantastic of an artist he truly is!

[@kevincompton2305]

He is great

[@fotorabia]

Its also inspiring from many creative levels...for other artists..what ever your medium may be...

[@dboboc]

And he’s repeating himself, a lot.

[@sonnyzeitgeist2570]

Very cool watching you work wiith acrylic. Great video.

[@carlhayes-ze5nd]

Good call on that back window. Extending it and keeping parallel lines made it look soo much better.

[@sloazone25]

Was not to sure about you when I first stumbled upon your content.. I was not at all. However that being true and said, I do appreciate what you are and have been doing and creating sir. I have become a fan and a believer in your methods and ideas. Well done!

[@robertcloosterman9336]

A few years back I worked for a company making windshields for funnycars etc. Roughly to what you are doing here. Except they were made from Polycarbonate. Similar to Plexiglass but shatterproof. Thanks for the good memories

[@vwcoco]

Wow !! Very interesting watching you form the front windshield and making it work.just excellent fabrication Chad

[@howardmarshall5713]

Hello Chad and Jolene. Another day of progress on the Merc. You'll get there eventually 🙂 . I love watching your project's develope. I know you read all these comments because you have mentioned a couple of my tips. Like lubeing the cups on the air bags. You can get a silicon spray that will create a bit less friction on the rise and fall of the bag I don't think the silicon spray will damage the cup or the bags.

[@AndysCrapCars]

Yes.... I've always avoided my car and motocycle projects missing glass, I'm looking forward to see the end result and possibly a fallow up of after some use to see its use. Excellent work proud to be Canadian seeing your work

[@i8ntnuts]

Even in the 60s the side glass from station wagons was often missing from cars in the wrecking yards. Flat glass even on cars from the 30’s was plentiful.

[@joeyb.9858]

Hello HILTZ MOTOR CO.. awesome to see you work on the windows, the learning experience is great to watch..

[@kk-ki2ci]

you should open a museum and show off all your art to the world

[@terrymccall1899]

Thank you both for all your hard work.

[@kennethamerine8026]

I am excited to see how to make a windshield! Chad is inventing what he needs at a low cost! Sweet!

[@markkurutz3544]

Can’t wait for tomorrow!😎

[@stevenaugustin6784]

Chad, you are an artiste! The way you are creating bucks and then windows is nothing short of genius! I'm more of a "restoration to stock" kind of guy, but this is awesome! LOVE these videos!

[@ate-updesigns9186]

Very cool...your exactly right on that back window..it does flow 100% better..the front metal window looks awesome..kinda reminds me of doc's sunglasses from back to the future...cant wait to see how this works...ingenious idea...thanks for the episode...see ya tomorrow Chad and jolene

[@amtperformance7072]

Great video! Very helpful and easy method to create a mold. The more patience you have when forming it, the better it will finally be. Well done!

[@cyborgbudda3374]

I am happy to see you do this. All at your place without missing a step! Thanks.

[@gbdrywall]

i love how you show your honest approach and how you go about it

[@pharpester]

Really nice template building, I like how you made the tape structure to put the paper on, very clever!

[@blackbirdcycles]

I made a comment saying it look OK buy the more you explained what you looking for the more I agree with you. Keep up the great work.

[@Zanehoward88]

When you were explaining how the plexi glass scratches and gets blurry. I though”I wonder if they make a clear wrap to put on it.” I thought of the peel away lens covers that dirt bike riders use. Then you made my day saying exactly that plan. I hope it works. Good luck with it!

[@darylmorgan9887]

Wow awesome job on the front and rear window and how you do it. Thanks Chad and Jolene. Never too old to learn something new.

[@rickhettwer854]

A wonderful idea Chad, I have been thinking about chopping my 39 Buick coupe, even though it basicly has flat glass all the way around, I'm thinking it may be cheaper to do this rather than buying glass for it. And It is something i can do myself. Thank you Chad man. More great filming by Jolene, also thank you for bringing us along.

[@jarvise.8166]

You are amazing and gifted! Love your work!

[@scottwilson1841]

You have to love Chads energy. He is definitely excited over this project. Keep up the great work.

[@thelastremaininglogicallib9320]

Yeah, this is the first time I've seen anything from him and it was obvious right away that his personality and enthusiasm could keep me watching. Interesting accent and as far as I know, I've never heard it anywhere. It's as if a Manitoba farmer accent had a baby with a Baltimore accent, then hired a Pennsylvania Amish accent to be its full-time, live-in nanny.

[@thelastremaininglogicallib9320]

Also, (please do not mistake this for criticism, because it's not) is he referring to Plexiglass? I assumed he was but I got to thinking, maybe its a different type of material, similar to Plexiglass but better for certain applications.

[@venombob3364]

not only are you good at what you do. You are good at explaining things so ppl can understand them keep it bro

[@gregpanek523]

Your windshield buck gave me an idea for a project. Thanks Chad!

[@dennisbackstrom2244]

Real craftsman, super nice man. Thanks for sharing

[@MongoLloyd74]

I've never used vinyl wrap, so my question is how heat resistant is it? Would it be possible to wrap the plexiglass while it's flat and THEN bend it on the drape mold? It seems like that would simplify the process greatly, providing it doesn't melt it. Also, for the side and back windows, you could apply the same principal to the Plexiglas using outdoor rated window tint. Even colored or chrome. It opens up a lot of possibilities.

[@laird340]

I worked in a plastic factory for 16 years that specialized in thermoforming. That's a good idea. If you could make a mold and thermoform the plastic, then take it to a glass shop, I think that would work better.

[@mr.moussestache5458]

Love the intensity and passion you have for what you do. Great content, keep it up.

[@robertdehaes9329]

This is a good subject to cover for a lot of applications.

[@annehiggins3559]

Thinking outside the box is a great way to move forward hope it works out thanks for sharing

[@craigspejcher8022]

Worked at a glass co. You shape has to fit in your rubber that locks the windshield in ,I think you are doing a great job I’ve been restoring a 57 Chevy Belair 2dr sedan in the paint booth this week top is Adobe beige bottom Sierra Gold

[@leehowell1225]

Super neet idea on the windshield and glass I like the inthusiastic way you do things .,I'm 70 and most the things on my cars have been fabricated by me because I can't afford the ones at the parts house .

[@mattnelson5322]

Good class today! Thanks for sharing!

[@jparish2469]

can see the flow in flow well done great show tonight thanks guys .good job you put the glove on Jolene

[@patcordingley2751]

gonna look awesome once glass goes in. nice work chad/jolene

[@DavidBrown-mn3iy]

Your excitement for the new idea is infectious. I look forward to watching it become reality.

[@waynebernier1061]

I watched the last video about the rear window, I agree the roof line didn’t look right. Didn’t really like the first window you tried, wrong shape for the car, I thought. The rectangular one reminded me of old limo rear windows, always a classy look to me. This video definitely shows where you were going with the view you wanted, it’s great from every angle, I think anyway. Your visions always prove true. I really appreciate your builds.

[@billgroel4463]

Great idea i’m always learning. Thank you for sharing

[@jeffreycrossin427]

There was a show called tanked. They made fish tanks out of acrylic. They didn't use the clear coating like you are thinking but they did the same thing with heating it into a shape. You might get some good ideas from the show on what to buy to get the best out of it. Thanks for doing the show is great 👍

[@stevenmackenzie8527]

Love how you are going to redo the back window. Thank you for the step by step instructions on how to make a window

[@danielmurphy4023]

I love the full step by step and how he makes it look so easy lol

[@davidtutor6763]

Love watching and learning. Thanks for the hard work you two

[@jaychandler62]

I like it with the smaller window, looks 100% better, good job

[@marygarner5249]

You are Amazing your creations are all you love it 😁😁😁😁😁💟

[@robertduvall7392]

I'm behind you 150% on this succeeding!

[@chrisheyer4966]

What an ingenious idea to use plexiglas with vinyl wrap. It opens up the possibility of chopping cars in ways that have always been limited to what can be done with glass. Basically no boundaries anymore if it works

[@willyg6545]

Not sure that will pass any inspection??

[@chrisheyer4966]

@@willyg6545 probably not you are right in that sense. I am in Georgia mountains we have no inspection here so I didn't think of that. Good point

[@markbeer9393]

You convinced me, I agree 100% about the back window now!

[@ricklynch7851]

The back window your making looks excellent

[@kaschinnasamy3821]

Your design for the rear window looks really great .excellent rear look.Cannot wait to see the front window.Kas Southafrica

[@bobclark5479]

What a Kool idea. Can hardly wait to see the finished windshield.

[@jeremyoshea7941]

You’re right it’s a good thing that you’re proud of yourself opened some minds up there, wow This helps me in my model building in RC fabricating it’s a small thing I do a hobby but it really helped me out thank you for your time!

[@kevinching1975]

It's great to see a craftsman at work great job Chad and Jolene for the fantastic video

[@maximejette7674]

I can't wait to see the final product...nice work

[@davebuckholts]

Nice work! I like the rear transitions now too. I liked the rear as it was but it does flow better now.

[@i8ntnuts]

The profile reminds me of a 55 or six Chevy sort of. Just looks familiar

[@davidwylie5921]

I love your ideas on how to build things

[@matthewfocke5360]

Window construction sounds like a great idea. Is it possible to mold glass windshield material over your metal form, if it could hold its height, width, and depth? Clear aluminum? If only... Windshield glass idea: Pepsi glass with a scratch-resistant layer, inside and out. Genius!

[@classic_cars8713]

can't wait for the next video on the glass, thanks for all the good ideas

[@Brian-uy2tj]

Little details mean a lot. Makes all the difference between good and great!

[@frankkirby5763]

Chad that is amazing. You are so talented. I APPRECIATE you and Jolene. I love your channel.