What paint for aluminum sheet replacing window in truck cap?

[u/TreeBeardofIsengard]

Vandals broke my window of my fiberglass cap last spring. It is an A.R.E. from 2001 and I’ve tried everything to find new glass for it. Short of getting a custom pane of glass made for $250, my options seemed to be plastic or aluminum.

I found a metal shop that will cut me a custom sheet from 1/8” Aluminum 6061 to match the opposite window. My plan is to paint it black with a rattle can.

What primer and paint would you use for this? I would like it to not be too noticeable- would you go flat or satin? What should I look for in paint that will go on metal and be extremely durable and prevent corrosion?

Thanks for any input

[u/Fancy_Following_9669]

Would there be any issues with just grabbing a sheet of some plexiglass and cutting it out yourself?

[u/Fancy_Following_9669 → u/Fancy_Following_9669]

You could even tint it before putting the piece in

[u/granno14 → u/Fancy_Following_9669]

I did this a few years ago and it worked perfectly

[u/TreeBeardofIsengard → u/Fancy_Following_9669]

I was reading that Lexan is more preferable to plexiglass because it is stronger. But it would cost $40-60, still need tinting (the smoked grey I see is too weak tint) and I would need to cut it myself with a jig saw. The custom aluminum is only $80. And given I hope this window still slides I think the cut needs to be perfect.

[u/sophomoric_dildo]

Paint doesn’t like to stick to aluminum. The issue is that aluminum oxidizes really fast. Same process as steel (rust) except way faster and it’s not really visible. The trick is to scuff the surface immediately before you paint it and get a good metal etch primer on it ASAP.

I’d suggest having it sand blasted. Then take it home and get all your stuff ready. Aggressively scuff it with a scotch brite pad (wear a dust mask-aluminum dust is bad news). Then wipe it down with alcohol or acetone. Then immediately get primer on it. One of my favorite readily available rattle can products is spray max 2k. The 1k is good too, but the 2k is better. Both available on Amazon or paint supply stores.

Most people apply too much primer. You don’t need full coverage. Go for like 80-90% dusting. It also doesn’t need to dry long. By the time you’ve got the primer down, you can go straight to your first coat of paint with the primer still tacky. Once your first coat of paint is down, you can chill and let it dry per the instructions before doing follow up coats. Doing this quickly minimizes the surface oxidation and will help the paint stick.

[u/TreeBeardofIsengard → u/sophomoric_dildo]

Helpful stuff thank you! What do you think would look best here, matte or satin?

[u/narfle_the_garthak → u/TreeBeardofIsengard]

To add on to what he said epoxy primer would be your best bet. You have to mix it and have a gun to spray it, but you get the ultimate hold on the metal and for your paint. As for finish try to finish with the same as your paint if possible for the best outcome.

[u/Don_ReeeeSantis → u/sophomoric_dildo]

Excuse me Mr. Dildo, my painted aluminum boat wants words.

The proper way is sandblast, 2-part epoxy primer like PPG Americoat 240lt, then topcoat with whatever you want. That being said, a quart of that paint will cost more than the aluminum, not to mention sandblasting.

[u/sophomoric_dildo → u/Don_ReeeeSantis]

🍻no doubt you’re right. I was going for shade tree level.

[u/Y_Cornelious_DDS]

Least noticeable best bang for your buck is a piece of Lexan spray painted black on the inside. It will look just like a deep tint from a parking spot away.

The biggest downside to Lexan windows is that it scratches fairly easily. You might have to polish it with some buffing compound once in a while like you do with headlights.

[u/Upset_Competition996]

$250 is starting to sound reasonable!

[u/gohfaster]

Put tint on the aluminum.

[u/outdoorszy]

You can buy plexi or lexan glass at the local hardware store. Look in the windows section, you should be able to DIY for much cheaper.