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colind
Joined: 10 Jan 2006
Posts: 32
Location: Sydney, Australia
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 Posted: Wed Apr 26, 2006 5:08 am Post subject: Fitting the Windscreen on KF IV |
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Hi Guys!,
Making steady progress with the build of my KF IV, and am presently trying
to fit the windscreen.
Bending the screen down at the front is fine, but when I start pushing it
back on the sides to make it meet the upper door pillars, I get very
aprehensive at the look of the compound curve that forms near the wing
attach point. There seems to be an awfull lot of tension there. I have not
been brave enough to try and push the sides all the way back - I have
visions a large crack appearing across the curve accompanied by a loud
snapping sound.
Are there any tips to doing this successfully? Is it OK to use a hot air
gun to try and ease the Lexan into the curve? Are there any long term
negative effects from using heat?
Regards
Colin Durey
Sydney
+61-418-677073 (M)
+61-2-945466162 (F)
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_________________
Colin Durey
Sydney
+61-418-677073 |
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asq1(at)adelphia.net
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| Posted: Wed Apr 26, 2006 6:09 am Post subject: Fitting the Windscreen on KF IV |
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The Polycarbonate that was used a few years ago was Bison,not Lexan. Maybe
there is no difference in formulation, but this is what worked for me.The
Bison worked quite well for that application,but it is best to cut a circle
as large as you can it that point and still have it covered by the nose
fairing. I found it best to do it on a really hot day or in a very warm
shop. After situating it the way I wanted,I VERY carefully warmed the whole
area(8"R?) w/ the heat gun. If you watch carefully you will see it begin to
relax. That is the time to stop.
My corners crazed eventually but by now it is time to replace it as it is
scratched from use and hazed from getting some petrol product on it. I got
8years and 400+ hours on mine,FWIIW. Larry Huntley
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bnn(at)nethere.com
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| Posted: Wed Apr 26, 2006 7:11 am Post subject: Fitting the Windscreen on KF IV |
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At 06:06 AM 4/26/2006, you wrote:
| Quote: | Are there any tips to doing this successfully? Is it OK to use a hot air
gun to try and ease the Lexan into the curve? Are there any long term
negative effects from using heat?
|
The guy that built mine built a hot box and heated the entire window to
about 185, letting it droop into place under it's own weight. First he
drilled and fastened the skylight portion of the window. He also fabricated
a female receiver for the bottom forward edge by splashing off the cowl.
(It was a crescent shaped carbon angle, about 2" wide.) Then he removed all
the covering paper and plastic. He covered the entire window with soft
cloth, felt or pile. He covered all that with space blankets taped at the
edges, leaving a hole in the bottom to which he attached some dryer tube.
The dryer tube had a crude deflector at the outlet so hot air would
disperse. At the other end of the dryer tube he loosely attached a heat gun
so cool would be inducted with the hot. He used some thermocouples to check
the internal temperature. Since his hot box was soft he was able to help
mold the window into place as it sagged. Once it had sagged close to
position he wrapped the windscreen against the bottom form and clamped the
sides to the frame. He then re-bagged and re-heated for some period. (I'm
not sure how long.) I have an extra-thick window, about .11", and it's
nicely formed.
Guy Buchanan
K-IV 1200 / 582 / 99.9% done, thanks mostly to Bob Ducar.
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Graeme Toft
Joined: 09 Jan 2006
Posts: 123
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| Posted: Wed Apr 26, 2006 2:12 pm Post subject: Fitting the Windscreen on KF IV |
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G'day Colin, great to hear your up to the windscreen. That must mean the
engines in and a goer. I fitted the screen on my Model 1 without problems
and that model has a tighter turn onto the skylight than the latter madels.
If you want to have a yarn, give me a call. The advice your getting
regarding applying heat is a question I have had for a while myself and I
will be interested in the results because I will be fitting a new one
shortly also. Got any pikies yet??.
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algate(at)attglobal.net
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| Posted: Thu Apr 27, 2006 4:59 am Post subject: Fitting the Windscreen on KF IV |
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Colin
I used to have the panel tank filler right in front of my windscreen and
during the warm summer months any minute spill of gas onto the windscreen
while filling resulted in crazing of the lexan. That being the case over a
period of two years I replaced my screen 3 times?? I have since done away
with this filler.............
Anyway that was just a background to let you know I have some experience in
fitting the windscreen
I use 1/8" tinted lexan (same as supplied with my kit) and as you point out
it is very stiff and looks like it will break when you try to bend down and
around to the vertical supports.
It won't!
I have found that a warm day works best but I don't apply any heat while
fitting. Basically I position the cut screen over the top and rivet at the
rear once I am satisfied with placement. Then I put the upright stainless
steel fairings in place and bend and slide the lexan into position each
side. I hold it in place initially with C clamps and fitted the front cowl
to make sure the fit between the windscreen and the cowl was right. Once
satisfied I drilled through the upright locations and bolted each side.
Then I completed all of the top riveting.
I do use a heat gun to relieve the stress in the two upper corners once
everything is in place and this seems to work really well - You can actually
see when the tension relieves under heat although it takes quite a lot. (I
practiced with scraps first but it is pretty forgiving)
I have subsequently replaced two of my friends windscreens and the last one
took 1 hour from the time we removed the old one and had the new one in
place.
Hope this helps
G.Algate
Lite2/582
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