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Windshield Installation

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icrashrc

Joined: 16 Mar 2006
Posts: 247
Location: Mishawaka, In

Posted: Wed Dec 31, 2008 2:05 pm Post subject: Windshield Installation

I'm about to start installing the optional windshield on my Mark III Xtra. I assume it's optional as there's no info in the building manual on it. LOL



Anyway, having never worked with Lexan before I'm looking for any words of wisdom on the whole fitting, cutting, and drilling process. We wrapped a couple ratcheting type straps around the blank piece provided by Kolb but the tension required to bend the Lexan seems to distort the tubing of cage a fair amount. Thanks,



Scott

slyck(at)frontiernet.net
Guest

Posted: Wed Dec 31, 2008 2:22 pm Post subject: Windshield Installation

Scott,  mine is not a MkIIIx -or even a normal MkIIIc but here is how  

I would

approach it:  1. given the blank is larger than the finished window,   

drill and cleco

one side first, possibly leaving extra to be trimmed if you are fussy.

2. wrap it to the other side, the first tube will not deform now  

because it is held in line with the clecos.

3.  drill and cleco the second side.

4. trim to size.

5. I used an orbital jigsaw on my 1/8" stuff and it worked well, had  

to clean up the cut with a mill file

6.  put masking tape on the cutting area.

BB



On 31, Dec 2008, at 5:05 PM, icrashrc wrote:



 	  Quote: 	
		   



 I'm about to start installing the optional windshield on my Mark  

 III Xtra. I assume it's optional as there's no info in the building  

 manual on it. LOL



 Anyway, having never worked with Lexan before I'm looking for any  

 words of wisdom on the whole fitting, cutting, and drilling  

 process. We wrapped a couple ratcheting type straps around the  

 blank piece provided by Kolb but the tension required to bend the  

 Lexan seems to distort the tubing of cage a fair amount. Thanks,



 Scott





 Read this topic online here:



 http://forums.matronics.com/viewtopic.php?p 22045#222045

jlsk1(at)frontiernet.net
Guest

Posted: Wed Dec 31, 2008 2:27 pm Post subject: Windshield Installation

If the windsheild is going to be riveted in place with 1/8 inch rivets, as 

it is on the MK-3C, then I cut the lexan slightly larger that the span 

required, with a jigsaw, with masking tape a buffer to prevent scratching of 

the material. I also used spring clamps to hold it in place for the repeated 

trial fit/ removal/ refit, etc. You will have to clamp the lexan in place 

several times, but eventually, drill thru it  to hold it  inplace for the 

fitting process.#6 screws will hold it while fitting instead of the rivets. 

clecos might work as well. I think I removed & installed mine at least a 

dozen times while fitting it to my frame. I also sanded with 120/ & 220 grit 

on the edges to get the fit right. It is tough stuff.But don`t  drill/fit it 

in with bowed cage tubing, sort of pre-curve the 2-3 foot span of the front 

cage  by hand. Once you are ready to permanantly attach ( with rivets) if 

thats how the MK-3X attaches), drill the 1/8 inch holes slightly over sized 

to allow for material expansion/contraction with temp change, before you 

rivet them on. If the MK#X doesn`t attach with 1/8 inche rivets, someone 

else chime in.

Jim Kmet

Cookeville, TN

MK3C

---

mdnanwelch7(at)hotmail.co
Guest

Posted: Wed Dec 31, 2008 4:26 pm Post subject: Windshield Installation

 	  Quote: 	
		   I'm about to start installing the optional windshield on my Mark III Xtra. I assume it's optional as there's no info in the building manual on it. LOL

 Scott

 
	


Mister Scott,

 

  Bob and Jim have both suggested some helpful tips.  I believe you will find Jim's idea of using 

those hand clamps the best way to temporarily hold the sheet in place for fitment.  

 

1)  If I were beginning my installation, the first thing I'd do is clamp one side securely with those hand-clamps(You should have about 10 on hand).  Then, start drilling along that one edge.

I found it worked out pretty good with a 3" rivet spacing.  Allow for at least 1/2" overhang on this side for final trimming.  Cleco it with about 20 clecos equally spaced. (about every 2nd hole, maybe more)

 

2)  Bend the windshield to final position using lots of those cushioned jawed hand-clamps and secure it so that that other post is not distorted.  Also, now you can put those clamps along the top and bottom edge.  Drill it out along the entire length.  Then drill it out along the top and bottom edge.  Apply clecos as needed.

 

3)  IIRC, I drilled my initial holes with 3/32 drill bits.  After I was completely done with the initial drilling on the frame, I opened all the holes up to 1/8".

 

4)  With regard to the Lexan holes, it was recommended to use a drill bit a teeny bit bigger than the 1/8" pop rivet.....say, .130 or so.

 

5)  I'm sure you remember my inquiry a little over a year ago about the design of the "plastic

products drill bit".  Our good friend, Rick Gerard supplied me with a drawing of the proper shape

of a Lexan drilling bit.  If you need a picture of it, let me know, I should be able to find it.

BTW, a "regular drill bit" just won't work.  It grabs and spirals into the plastic, rather than cutting away the material.  It is very, very important to use the proper drill bit for plastic drilling.

 

6)  I found that a high-speed grinder with a 1/16" cutting disc worked okay for trimming an edge.

But, do NOT go slowly, keep a good pace, or it can melt the edges.  Doesn't ruin it, just makes more work to trim the melted part.

 

  There you go.  More information than you need.  Oh, BTW, when Jim K. said he installed/removed his 12 times, he may have meant 120 times....at least it seemed that many times for me.

 

  In a month or two, after you finished all your Lexan pieces, have a party and celebrate.  I

felt like that was one job I truely underestimated how much work it was.

 

Best to ya,

Mike Welch

MkIII

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Snoopy Baxley

Joined: 09 Jan 2006
Posts: 42

Posted: Wed Dec 31, 2008 8:49 pm Post subject: Windshield Installation

Scott you have had some good suggestions on your windshield project  but if your like me and got your windshield kit from Kolb you opened the box to  find a sheet of semi-precut Lexan and some metal tubing parts. Makes you  want to scratch your head a lot if you have never put one of these on before.  

 After I got my railing and bows mounted in place on my Kolb  .  I then used a big piece of card board to go over the bows to use as a pattern  for my Lexan . I cut and trimmed my card board till I had it fitting just right  . Then I placed it on my sheet of Lexan and marked it out. I allowed a little  extra on each end to trim off later if I didn't need it . I thought this would  work better than handling that big piece of Lexan. I too used a rotary disk to  cut my Lexan also. It worked out good . 

  

 Stephen



Stay up-atest news - from fashion trends to celebrity break-ups and everything in between.

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icrashrc

Joined: 16 Mar 2006
Posts: 247
Location: Mishawaka, In

Posted: Thu Jan 01, 2009 8:13 am Post subject: Re: Windshield Installation

Thanks to all for the tips. What kind of rivets should i use, aluminum or stainless?



For drilling i have one of these bits. Anyone use one of these?



http://www.aircraftspruce.com/catalog/mepages/plexicuttool.php



Sorry, i see i put the worng link in the first time around. Here's the drill bit...



http://www.aircraftspruce.com/catalog/mepages/plexidrill.php

_________________
Scott

www.ill-EagleAviation.com

do not archive

Last edited by icrashrc on Thu Jan 01, 2009 11:50 am; edited 1 time in total

williamtsullivan(at)att.n
Guest

Posted: Thu Jan 01, 2009 9:23 am Post subject: windshield installation

Scott:  That tool works fine on plexiglass, but I don't know if it will work on Lexan.  I can tell you that if it gets dull, use a chain saw file to sharpen it.  Use a good straight edge- the tool will track off if you're not careful.  I have used it on a lot of plexi up to 1/4".  Score multiple times from both sides on the thick stuff, and use a firm clamping board on both sides before snapping off.  Practice on scrap first.  Let us know if it works on the Lexan.

   The rivets probably depend on what you are going into- aluminum or steel.

  

                                                 Bill Sullivan

                                                 Windsor Locks, Ct.

 [quote][b]

John Hauck

Joined: 09 Jan 2006
Posts: 4639
Location: Titus, Alabama (hauck's holler)

Posted: Thu Jan 01, 2009 11:42 am Post subject: windshield installation

I use aluminum rivets, hardware store  variety, for lexan.  Primarily, because it will have to be replaced sooner  than one expects or wants to.  Drilling out aluminum is much easier than  steel.  Also reduces the chance of enlarging the rivet hole in the  frame.  When you get an old airplane like mine, you will eventually go to  larger diameter rivets to adapt to the larger holes.

  

 john h

 mkIII

 Woodville, Florida 

 [quote]   



                             The rivets probably depend on what you are going into- aluminum or          steel.

          

                                                                  Bill Sullivan

                                                                  Windsor Locks, Ct.

 	  Quote: 	
		   	
[b]

_________________
John Hauck
MKIII/912ULS
hauck's holler
Titus, Alabama

mdnanwelch7(at)hotmail.co
Guest

Posted: Thu Jan 01, 2009 12:08 pm Post subject: windshield installation

John C group C

  

   I just made this same suggestion to Scott "off list".  I had to drill out some SS rivets in Lexan C and they

 have a tendency to spin and melt the hole's inner surface.   This taught me: Aluminum rivets definitely are the way 

 to go for Lexan installation. 

  

 Mike Welch

 MkIII

  

     I use aluminum rivets C hardware store variety C for lexan.  

 john h

 mkIII

 Woodville C Florida

  

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icrashrc

Joined: 16 Mar 2006
Posts: 247
Location: Mishawaka, In

Posted: Fri Jan 02, 2009 3:50 am Post subject: Re: Windshield Installation

Thanks to all again. I assumed aluminum rivets but thought i should ask.

_________________
Scott

www.ill-EagleAviation.com

do not archive

icrashrc

Joined: 16 Mar 2006
Posts: 247
Location: Mishawaka, In

Posted: Sat Jan 17, 2009 3:39 pm Post subject: Re: Windshield Installation

I've started the windshield installation page.



http://www.ill-eagleaviation.com/windshield_installation.htm



My saber saw works well for cutting Lexan. The Plexiglas drill bit from Aircraft Spruce also works well. Thanks to all for the help and suggestions.

_________________
Scott

www.ill-EagleAviation.com

do not archive

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