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PMorel
Joined: 09 Jul 2007
Posts: 62
Location: Locust Grove, GA USA
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 Posted: Sun Aug 30, 2009 6:27 am Post subject: Old Lexan wind shield material |
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Just a note to let everyone know the problem I had with my lexan wind shield. I just finish my Speedster last month and the lexan I installed was .90 but came with the kit back in the early to mid 90's. Cutting and fitting was pretty straight forward and had no problems with the installation. Nylon cargo straps is a good way to fit the lexan and the compound curves was a big concern but it all went together nicely.
About a week or two before I made my first flight, I got all kinds of crazing (sp) on the lexan where the compound curves are in each of the upper corners. I would have expected this after a few years and once the UV rays got to it, but not right away and just after peeling the backing off just months before.
My advice to anyone still in the building stages that still has not installed an aged lexan sheet may want to consider getting a fresh or new sheet of lexan to avoid this.
Paul Morel
912 Speedster
Locust Grove, GA
[quote][b]
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Paul Morel
912 Speedster
Locust Grove, GA
www.WingsAirPhotos.com |
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larry huntley
Joined: 19 Jul 2008
Posts: 149
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| Posted: Sun Aug 30, 2009 6:45 am Post subject: Old Lexan wind shield material |
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Paul,
I think mine was Rhino polycarbonate sent in the kit in 92. Didn't fly it til 98. Relieved stress in those corners w/ a heat gun when I installed it. I also cut the corner cutouts as large as I could cut them and still be covered by the fairings. Flew it for 10 yrs 400+ hrs. Crazed some a couple of years ago and I replaced it mostly because of scratches and hazing. Did you heat the stressed area? Larry
[quote] ---
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Larry Huntley,Dundee,NY
Kitfox 4-1200 N234EE
EA81,AMAX Redrive Warp 3 blade |
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PMorel
Joined: 09 Jul 2007
Posts: 62
Location: Locust Grove, GA USA
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| Posted: Sun Aug 30, 2009 7:11 am Post subject: Re: Old Lexan wind shield material |
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Larry
No, I didn't heat the corners, and looking back, that is something I should have done. My kit was also purchased in 92' but not completed until 09'. 17 years is a long time for lexan, hoses, bungee cords, and other plastic items to be sitting idle. I'm not saying that these items aren't perfectly usable, but just keep that in the back of your head as you're building.
Paul
912 Speedster
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lcfitt(at)sbcglobal.net
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| Posted: Sun Aug 30, 2009 8:42 am Post subject: Old Lexan wind shield material |
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Polycarbonate sheets come in .060, .093 and .118 thickness for our purposes.
As it has been mentioned many times the higher VNE of the Speedster has to
do with the thickness of the windshield material and the lower tendency to
bend inward at high speeds. As I recall, the early thickness for the
Speedster was the .118 (1/8"). It was very difficult to install and crazed
readily. Then came the .093 for the Speedster and the long wing IV stayed
at the .060. Even the .060 will craze in time. If you look at the minimum
radius in the spec. sheet ( radius equals at least 100 times the thickness).
That means that for the original 1/8" speedster material the minimum bend
radius is a tad over 12 inches. For the .093 a bit over nine inches and the
.060 six inches. The following link is for the GE version of Polycarbonate.
http://www.tapplastics.com/uploads/pdf/Polycarbonate%20Fabrication%20Guide.pdfIt is pretty obvious with our usage, the radius we need at the wing root isreally stretching it for the thin variety and way beyond tolerances for the.093 and .118. Heating is a good idea, but be cafefull, there, asPolycarbonate has a significant tendency to absorb moisture, and if the heatgun temps exceed about 250° bubbles can form in the sheet.I have flown for years with minor crazing in the corners yet there have beenseveral cases where the windshield has split from tahe bend to the cowl.Lowell FittCameron Park, CASecond Build Model IV-1200 R-912 ULCovering left wing---
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larry huntley
Joined: 19 Jul 2008
Posts: 149
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| Posted: Sun Aug 30, 2009 9:10 am Post subject: Old Lexan wind shield material |
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Sounds like good advice. A lot of materials ( like the shock cords) have a
definite shelf life. Good luck with your Fox. It is a wonderful bird.
Larry
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Larry Huntley,Dundee,NY
Kitfox 4-1200 N234EE
EA81,AMAX Redrive Warp 3 blade |
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Lynn Matteson
Joined: 10 Jan 2006
Posts: 2778
Location: Grass Lake, Michigan
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| Posted: Sun Aug 30, 2009 10:47 am Post subject: Old Lexan wind shield material |
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Or bite the bullet and get a pre-formed windshield from LP
Aeroplastics, or through John McBean. The thicker material used in
the preformed units will give you peace of mind when you're headed
toward a flock of seagulls.
Lynn Matteson
Kitfox IV Speedster, taildragger
Jabiru 2200, #2062, 744.1 hrs
Sensenich 62"x46" Wood prop
Electroair direct-fire ignition system
Rotec TBI-40 injection
Status: flying
On Aug 30, 2009, at 10:33 AM, Paul Morel wrote:
| Quote: | Just a note to let everyone know the problem I had with my lexan
wind shield. I just finish my Speedster last month and the lexan I
installed was .90 but came with the kit back in the early to mid
90's. Cutting and fitting was pretty straight forward and had no
problems with the installation. Nylon cargo straps is a good way
to fit the lexan and the compound curves was a big concern but it
all went together nicely.
About a week or two before I made my first flight, I got all kinds
of crazing (sp) on the lexan where the compound curves are in each
of the upper corners. I would have expected this after a few years
and once the UV rays got to it, but not right away and just after
peeling the backing off just months before.
My advice to anyone still in the building stages that still has not
installed an aged lexan sheet may want to consider getting a fresh
or new sheet of lexan to avoid this.
Paul Morel
912 Speedster
Locust Grove, GA
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contribution_-
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Lynn
Kitfox IV-Jabiru 2200
N369LM |
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brubakermal(at)yahoo.com
Guest
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| Posted: Mon Aug 31, 2009 3:35 pm Post subject: Old Lexan wind shield material |
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my corners where not heated they crazed. my kit was about a 87 ser no347 not finished till 99 and the bungees went limp quicker than the new ones i installed. I need to find some lexan that i can pick up in Oshkosh while I am at the 120 hr course next week. mal mod 2
--- On Sun, 8/30/09, PMorel <pmorel(at)bellsouth.net> wrote:
| Quote: |
From: PMorel <pmorel(at)bellsouth.net>
Subject: Re: Old Lexan wind shield material
To: kitfox-list(at)matronics.com
Date: Sunday, August 30, 2009, 3:11 PM
--> Kitfox-List message posted by: "PMorel" <[url=/mc/compose?to=pmorel(at)bellsouth.net]pmorel(at)bellsouth.net[/url]>
Larry
No, I didn't heat the corners, and looking back, that is something I should have done. My kit was also purchased in 92' but not completed until 09'. 17 years is a long time for lexan, hoses, bungee cords, and other plastic items to be sitting idle. I'm not saying that these items aren't perfectly usable, but just keep that in the back of your head as you're building.
Paul
912 Speedster
Read this topic online here:
http://forums.matronics.com/viewtopic.php?p=260474#260474
-= --> http://www.matronics.com/Navigator?Kitfox-Li --> http://www.matronics.c===================
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[quote][b]
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