how to replace broken window(s) in a truck topper?

[lloyd3]

My '97 Ford Pickup project is rapidly becoming a money pit.  It needs new belts, hoses, tie-rod ends, ball joints and possibly a new clutch (everything's still original and mostly worn out).  Because of all the unplanned-for expenses, I opted for a used truck topper instead of a used camper for it (trying to keep my gear dry and secure as I drive it cross country). I found a decent '97 Ford-sized topper for it for minimal money, but it has two windows missing (front & side).  It looks like autoglass folks don't do this and replacement parts are prohibitively expensive. Has anybody here performed such a repair with lexan or plexiglass?

[FJMG]

I work on construction sites so yes.......I replaced my rear glass many times on my 97 dodge with plexiglas, easy to cut and fit to window frame.
As for the front, I went a different route........
Since I had a rear sliding window on the cab of the truck, I secured a "gasket", comprised of O/H door bottom panel weatherstripping (the one for wood doors that is over 2" wide), to the topper and removed the front glass in the topper altogether.
This created a seal between the topper and cab which allowed me to carry 14' finishing material in the rain, not to mention allowing my kids to open the rear slider and access my cooler for food and drink.

[lloyd3]

FJMG: thank you for that. So....you cut to fit and then flex into place? I would assume you could then put in a  bead of silicone to fill the channel & complete the seal?

[FJMG]

My unit had a metal window frame that comprised of a u channel with rubber gasket where the "glass" was inserted. This frame probably started out as a straight piece that was bent by the manufacturer to suit the perimeter of the window and joined together.

I removed the frame with broken window and separated the joint, this allowed for easy insertion of newly cut plexi.

Just look for this joint in your front window metal frame.

As for the side, if a slider, remove the unit and look for screws to disassemble the frame.

If you really want to "cheap out" then remove the front window frame altogether and cut a piece of plexi about an inch larger than the opening all the way around and pop rivet (or bolt with some 10-24 bolts) directly to the shell and silicone!