Extreme Windshield Installations

[CanadianSheepHunter]

Clamping a strip of Lexan that is the same thickness as windshield so I can trim the sides of the fibreglass former down until the Lexan that is clamped down is level but not higher than my mock firewall. I had previously trimmed the firewall edge of fibreglass former bottom.

[CanadianSheepHunter]

With the fibreglass former(comes with Extreme windshield Kit) flat against the mock firewall it’s aprox 26 degrees...this is where the Lexan windshield will attach to the top side of the fibreglass former.

[CanadianSheepHunter]

The angle is close but the top of the windshield bracket is higher and this is why the firewall will need to be flexed slightly forward so that the angle on the top of the fibreglass former matches the top of the front windshield bracket.

[CanadianSheepHunter]

With a straight edge from top of the fibreglass former(with the former flat against the firewall) the angle is 29 degrees...so a 3 degree difference at the moment...BUT this angle will increase as I trim the sides of the fibreglass former until it’s flush with the top of firewall(with the thickness of Lexan allowed for)

[CanadianSheepHunter]

I had a sheet metal guy bend the piece you see below the aluminum angle with a brake(that is what’s called the sunroof extension)...the angle is not perfect but I think it will be ok as the Lexan should flex enough to conform to the curve...I hope!

[CanadianSheepHunter]

Another view

[CanadianSheepHunter]

Sides of fibreglass former not trimmed yet

[CanadianSheepHunter]

Sides of fibreglass former not trimmed yet, this pic is taken with the fibreglass former flat against the firewall.

[CanadianSheepHunter]

Pic taken with former flat against firewall.

[CanadianSheepHunter]

Trimmed 1/4” off the bottom of the sides of the fibreglass former, need to trim more just going slow so I don’t trim too much!

[CanadianSheepHunter]

Trimmed another 1/4” off the bottom sides of former since last pic...starting to get close now.

[CanadianSheepHunter]

Getting close but the fibreglass former is still too high by about two thicknesses of the Lexan windshield.

[CanadianSheepHunter]

Fibreglass former trimmed down more on sides and also had to take the thickness of Lexan off the bottom front edge of it too. I will have to trim the bottom sides of the former a bit more to match the angle going up to the windshield bracket. These pics of the angles I forgot to level the fuselodge first for proper reference but the tail is 2.5 degrees higher than level in these pics. Angle on the angle finder is 30.5 degrees in this pic.

[CanadianSheepHunter]

Showing the tail is 2.5 degrees high in reference to the other pics with angles taken.

[CanadianSheepHunter]

Trying to show how much mock firewall is above the former(I’m holding up the titanium to try and not have clutter in background of pic.