Re: 92 Bayliner Capri windshield
Lexan will hold up just fine being bent. Even if it starts to craze in 5 years, it will be cheap and easy to remove and use as a template to cut another piece. Look in the yellow pages for plastics suppliers, they sell lexan (polycarbonate) much cheaper than the home depot. 1/8th in lexan will bend without heating for the curve of your windshield. It cuts easily with a sabre saw and fine tooth blade. Look at the MFG project in my signature below, the windshield is 1/8" polycarbonate cold bent. Its holding up fine, but does have a few craze marks in the tight upper left and right corners. That was about a $50 piece of polycarbonate from a plastics supplier.