We are using .25" thick lex an on the 496 liner. I designed the car to use a "flat wrap" windshield. This means we lay a piece of paper over the entire windshield and it will not have any gaps or wrinkles. We then made a casting of our windshield area (female) and found a local company that did vacuum forming. It was not vacuum formed but the vendor put it in his big oven to soften the lexan enough for it to take the form of the mold. All was fantastic but I did not no that there was windshield grade lexan that is much flatter than regular consumer grade. It might be good to make a practice piece from the lesser expensive grade along with the good one. If the practice piece turns out alright, you will have a spare..
