Extreme Windshield Installations

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Re: Extreme Windshield Installations

Postby CanadianSheepHunter » Sat May 23, 2020 1:40 am

Front edge trimmed to leave a 1/8” gap to firewall for expansion, but need to the the front edge clean yet.
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Re: Extreme Windshield Installations

Postby CanadianSheepHunter » Sat May 23, 2020 1:44 am

Lots of clamps !
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Re: Extreme Windshield Installations

Postby CanadianSheepHunter » Sat May 23, 2020 1:46 am

Now to mark the sides.
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Re: Extreme Windshield Installations

Postby CanadianSheepHunter » Thu May 28, 2020 11:50 am

The Diablo Diamond Blades from Home Depot sure work excellent for cutting Lexan. The 4 1/2” diameter blade is just the right size on a small grinder. An Oscillating cutting tool works excellent too, but I prefer the Diablo blade...less mess too.
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Re: Extreme Windshield Installations

Postby CanadianSheepHunter » Thu May 28, 2020 12:31 pm

Just showing the Diablo Diamond wheel cutting blade on a grinder, and the Milwaukee Oscillating tool with two of the blades I tried with it, both tools are great for cutting Lexan but I prefer the Diablo wheel blade cutter.
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Re: Extreme Windshield Installations

Postby CanadianSheepHunter » Thu May 28, 2020 6:24 pm

The sanding block attachment for the Oscillating tool is excellent for sanding the Lexan edges, and corners. Also a coarse file.
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Re: Extreme Windshield Installations

Postby CanadianSheepHunter » Thu May 28, 2020 6:34 pm

Installation complete except for painting the brackets and former. The Lexan mock firewall I used was 0.12” thick which was too thick because when you need to bend the top of firewall forward aprox 10 degrees to get the top of the Fiberglass former at the proper angle the heavy Lexan would bend ok at the high point at the Center but was too stiff towards the sides...so I ended up replacing the Lexan windshield that I had cut too short along the firewall. When you start putting clecos’s into the Fiberglass former through the Lexan windshield make sure the former is fully contacting the inside of the windshield...I didn’t catch that and that’s how I screwed up.
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Re: Extreme Windshield Installations

Postby CanadianSheepHunter » Thu May 28, 2020 6:37 pm

Trying to show the 1/16” to 1/8” gap between firewall and Lexan for expansion.
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Re: Extreme Windshield Installations

Postby CanadianSheepHunter » Thu May 28, 2020 6:40 pm

Not finished with the vertical door metal.
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Re: Extreme Windshield Installations

Postby CanadianSheepHunter » Thu May 28, 2020 6:45 pm

Can’t wait for the metal brackets to be painted.
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Re: Extreme Windshield Installations

Postby CanadianSheepHunter » Thu May 28, 2020 6:50 pm

Door metal
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Re: Extreme Windshield Installations

Postby CanadianSheepHunter » Thu May 28, 2020 6:55 pm

I may trim some metal off the top left of vertical door metal later, some tuck it under the windshield bracket above it, I will be painting them black then cover the junction point with black Sailcloth tape(used it on the Lexan on my Chinook), or with some Black Oratex, but the Sailcloth tape is much easier.
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Re: Extreme Windshield Installations

Postby CanadianSheepHunter » Thu May 28, 2020 6:59 pm

Because I never had the proper angle on the Fiberglass former all the way to the edges I ended up trimming the Fiberglass former too short, so now I plan to add a small trianlge of Fiberglass to the bottom that I cut too short, you can see the washer from the Cleco is very close to the bottom edge.
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Re: Extreme Windshield Installations

Postby CanadianSheepHunter » Thu May 28, 2020 7:03 pm

Trying to show the full contact of the windshield to the Fiberglass former all the way to and including the right edge. The Titanium firewall is installed.
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Re: Extreme Windshield Installations

Postby CanadianSheepHunter » Thu May 28, 2020 7:08 pm

Left side
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