Originally Posted by jredone
Looking like this is the route I may have to go.
In the event you do go that route a small note is the glass being curved will NOT directly transfer to an in-the-flat tracing when/if a panel were to be made that way.
I considered doing this to my van on the five windows I would be covering. I applied two-sided tape around the periphery of the windows and trimmed it flush with the glass edge. I then spread a heavy paper over the glass making sure to carefully match the curve before pressing it against the two-sided tape---trim the paper to match the glass shape.
Once this is done you have an accurate template from which a metal plate could be cut. One thing that kept me from doing this was my concocted method would have run a lot of money and time as I wanted the finished product to look like the deep tinted factory glass AND have the outer surface of the metal be flush with the body. That would not have been easy. I'd have had the panels painted a color resembling the tinted glass so it looked nice. That would have required the panels being painted and wet sanded and buffed before installation.
So naturally there's an easier way to do this if aestetics are NOT the main goal.
JRRedone if you do this please document your process and finished result--as best you can anyway. I know others here would be very interested.