New Windshield Option!!

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New Windshield Option!!

Postby BDA » Tue Jun 11, 2019 3:47 pm

I finally finished the extreme windshield install!!

Richard Holtz (Sheepdog) has come with something really great here!!

For those of us that want the most visibility possible - he virtually eliminates the boot cowl and runs the windshield all the way to the firewall.

My biggest gripe with factory setup was that big boot cowl right in the line of sight when setting up to land, and this fixes it. I am really excited about this and cant wait to flight test!

He created a structural former that mounts to the firewall and a new windshield mount system so that most of the bootcowl fiberglass is removed

I still need to trim the sides down in these pics, all that is left is the tube width.
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SuperStol XL With Titan 340
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Re: New Windshield Option!!

Postby BucF16 » Tue Jun 11, 2019 6:09 pm

Oh Crap, I guess I have to fork out more money!!! Richard, Do you provide the boot cowl. I'm about to order my 914 cowl form Just. That is the cowl the Steve Henry uses for his Apex set up. Is that the windshield he is using? My guess is, it is. You can PM me if you wish.
Let me know the price. Thanks!
Bruce
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Re: New Windshield Option!!

Postby SheepdogRD » Tue Jun 11, 2019 11:30 pm

BucF16 wrote:Oh Crap, I guess I have to fork out more money!!! Richard, Do you provide the boot cowl. I'm about to order my 914 cowl form Just. That is the cowl the Steve Henry uses for his Apex set up. Is that the windshield he is using? My guess is, it is. You can PM me if you wish.
Let me know the price. Thanks!
Bruce

Yes, this is the windshield and boot cowl that Steve has on YeeHaw 7. I talked to him tonight, and he says he has 30 hours on it, and it's working fine. He likes the improved visibility. and he'd do it again.

The Extreme boot cowl replaces the 914 boot cowl; there's also a fiberglass former and 4 aluminum parts. We'll be working out the kit price in the next few days.
Richard Holtz
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If just enough is really good, then too much ought to be perfect.
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Re: New Windshield Option!!

Postby Mhutton » Wed Jun 12, 2019 6:40 am

How do I order one of these? Can I easily retrofit this to a Superstol with a 912?
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Re: New Windshield Option!!

Postby Clark in AZ » Wed Jun 12, 2019 8:50 am

Is the windshield molded or is it the regular Lexan that you have to bend?
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Re: New Windshield Option!!

Postby BDA » Wed Jun 12, 2019 11:30 am

This is still the flat lexan windshield
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Re: New Windshield Option!!

Postby SheepdogRD » Wed Jun 12, 2019 12:21 pm

Mhutton wrote:How do I order one of these?

We're working out the order system. Give us a week or two and we'll be ready.

Mhutton wrote:Can I easily retrofit this to a Superstol with a 912?

We haven't tried a retrofit, yet, but it appears that some builders may be able to use the existing 912 cowling. That will depend on the way the cowlings were installed. It might be an "easy" job for some builders, but I expect it may take some fiberglass work to modify the width of the upper cowling. I'm working on a template that could be compared to an existing cowling to determine how this will fit; we'll have to try it on a few airplanes to see how well it works.

The 914 cowling is a similar situation. We're going to see if a retrofit is possible using the existing cowling with, or maybe even without, some fiberglass work. Some of them may need a new upper cowling.

Clark in AZ wrote:Is the windshield molded or is it the regular Lexan that you have to bend?

This design uses the Lexan from the kit. For retrofits, a new sheet of 3/32" scratch-resistant Lexan is best.
Richard Holtz
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Re: New Windshield Option!!

Postby stede52 » Thu Jun 13, 2019 11:22 am

I like the shape of the windshield, however, I have only two concerns based on my experience building windscreens and using Lexan: 1. I've used every kind of polish possible on lexan (polycarbonate) and you can never get the micros scratches out of the glass that leaves a hazy windscreen in time which is why certified aircraft don't use it on windscreen, and 2. the non-heated bend radius bend of 3/32 lexan is considerable greater then then the corners required on the Highlander windscreens. The end result is that it will eventually start forming cracks (crazing) at those bends because the lexan is under so much tension. I think most of you have already experienced this with the original lexan windscreen material which was only 1/16".
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Re: New Windshield Option!!

Postby SheepdogRD » Thu Jun 13, 2019 9:54 pm

I'm glad you like the shape, Steve, and I think your concerns are valid. I wish there could be a middle road between plexiglass and Lexan. We had to choose a material that worked for the most people, and, like the factory, we chose Lexan.

Plexiglas can be polished, and that's an advantage. But plexiglass is relatively rigid, and it's not very forgiving of installation mistakes. A plexiglass windshield would require shipping, and the Lexan is already in the builder's hands.

The crazing in Lexan is a slow process, but it does occur. It seems to be the primary reason builders replace their windshields after several years of flying. I researched the crazing issue, and I talked to two product specialists about our application. Both suggested that, with the bend radius on the Extreme windshield, the crazing would still take place over a period of years. Both product specialists recommended using scratch-resistant Lexan. One also suggested that we clean the windshield by flushing it with lots of water and gentle application of a microfiber cloth and mild soap. He noted that Lexan doesn't like gasoline.

A high percentage of builders are first-timers, so the windshield is probably their initial experience with Lexan. It's a surprisingly workable material. It's much more forgiving of cutting, drilling, and fastener-installation mistakes, and it doesn't stress-crack. Several years ago, I took some 3/32" Lexan and made 60-degree and 90-degrees bends in a brake. The bends came out perfectly, and today there is still no crazing or whitening in those hard bends.

Lexan has the cost advantage when it comes to replacing a windshield. Replacing with a plexiglass windshield means buying (and shipping) a whole new preformed part. But, with Lexan, we get a new windshield for the cost of the Lexan material (and shipping). We can flatten out the old Lexan windshield and use it as a template. And a builder can cut two Extreme windshields from a single sheet of Lexan, so there's a no-added-cost spare for use several years later.

Lexan windshields are far more resistant to birdstrikes and other impacts, where plexiglass can shatter. My friends who race stock cars won't touch plexiglass for windshields, though I think they're far more likely to need protection from hard objects than we will be.

Despite the advantages of Lexan, some builders might still prefer a preformed plexiglass windshield. I hope that the guys who plan to provide plexiglass standard windshields will develop a mold for the Extreme windshield. It'd be good to let builders choose.
Richard Holtz
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If just enough is really good, then too much ought to be perfect.
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Re: New Windshield Option!!

Postby stede52 » Tue Jun 18, 2019 12:43 pm

I agree, there are definite advantages and disadvantages in using the two materials and its always good to have options.

I have also used the scratch resistant poly-carbonates and my experience with it using lots of water, soap and microfiber (in accordance with poly-carbonate product people) wasn't much different then regular poly-carbonates. However, using that technique will definitely keep the poly-carbonate as clear as possible for longer. Another technique they use to keep the glaring down is to never clean your windshield using circular motion, always use vertical swipes, this helps cut down the glare aspect caused when the sun is at that bad angle.

Just fyi on the bending poly-carbonate in a break, when doing so, somehow the brake actually releases all the tension at the sharp bend and that's why it won't craze. When you just bend the poly-carbonate for the corners of a windshield the tension/energy never releases until it starts to crazing and it happens faster as the material gets thicker and the bend gets tighter. I've had it start crazing after a month when using 1/8" poly-carbonate (which I definitely don't recommend because its really tough to bend) and as soon as a year using the 1/16", however, that is not always the case and it may last for a couple of years before you see any crazing. I think it has to do with the poly-carbonate formula used by different manufacturers.

I definitely don't want to discourage people from using it because it's definitely a lower cost option, I just wanted to forward some information about using poly-carbonates. :D
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Re: New Windshield Option!!

Postby danerazz » Wed Jun 19, 2019 2:28 pm

Speaking of molded windshields, any news on the new supplier?
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Re: New Windshield Option!!

Postby stede52 » Sun Jun 23, 2019 11:34 am

I know Kris is in the process of building them now
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Re: New Windshield Option!!

Postby danerazz » Sun Jun 23, 2019 3:44 pm

...perhaps a slight re-profile would be in order...
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