I did this years ago. I've actually done 2 of them in different thicknesses. It's about as easy as taking the old out, and use it as a template on your sheet. I'm a little foggy, but one plastic is impact resistent, but scratches, the other is scratch resistent, but doesn't have the impact strength. I went for impact strength. The oe glass is 1/4" thick. My first window was at 3/16 and IIRC weight went from about 11 lbs to 3.5ish. Then for kicks I decided to try 1/8" and dropped another pound.
Be aware, care must be taken when cutting as not to crack the plastic. Also, with my thinner replacement you can feel it move in the weather stripping but hasn't leaked, and it's been 9 years. This winter I'm going to apply a light tint to it as the plastic is clear versus the tint of the oe glass. |