Extreme Windshield Installations

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Re: Extreme Windshield

Postby BDA » Thu May 02, 2019 3:40 am

Richard sent me this setup and I am Stoked!!

Really nice pieces, great instructions, nice quality glass work.

I will be installing this weekend!!

Really hoping it will work with the Titan

Thanks Richard!!
SuperStol XL With Titan 340
#486 - N331AK
Shawn Taplin
Mods in progress: Wing extensions, Airfoil tail ribs
Goal: 15mph no wind
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Re: Extreme Windshield

Postby BDA » Tue Jun 11, 2019 2:10 am

I finally finished the extreme windshield install!!
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SuperStol XL With Titan 340
#486 - N331AK
Shawn Taplin
Mods in progress: Wing extensions, Airfoil tail ribs
Goal: 15mph no wind
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Re: Extreme Windshield

Postby BDA » Tue Jun 11, 2019 2:49 am

The SS XL requires a few changes to the instructions.

Because the SS windshield top bracket is higher than the highlander the new former for the top of the firewall must be angled more OR mounted higher.
I angled mine.

I had already installed my cowling, so to fit the new bootcowl to the top cowling required some trimming.

I pushed the new bootcowl about an inch past flush w the former and trimmed the cowl lip to 2”

Then I trimmed about 3” off of the top cowl to fit the bootcowl lip.

Then I trimmed a wedge off each side of the top cowl, about 5/8” at the back to zero at the front corner.
SuperStol XL With Titan 340
#486 - N331AK
Shawn Taplin
Mods in progress: Wing extensions, Airfoil tail ribs
Goal: 15mph no wind
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Re: Extreme Windshield

Postby BDA » Wed Feb 19, 2020 1:46 am

I have made the final install of the Extreme windshield on my SS 340 XL (Alaskan)

The added visibility is amazing!

And I really like the look of the new boot cowl with the clear side panels.

I will post more pictures when I get it out of the shop.
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SuperStol XL With Titan 340
#486 - N331AK
Shawn Taplin
Mods in progress: Wing extensions, Airfoil tail ribs
Goal: 15mph no wind
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Re: Extreme Windshield

Postby CanadianSheepHunter » Wed Feb 19, 2020 2:12 am

I like it...I like it a lot I’ll be doing the same with a Rotax Edge Engine
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Re: Extreme Windshield

Postby Clark in AZ » Wed Feb 19, 2020 9:31 am

Very Nice! I'm getting ready to do mine. Any tips, tricks, gotchas???

Clark
Building SuperSTOL Kit 512
Cave Creek, AZ
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Re: Extreme Windshield

Postby BDA » Wed Feb 19, 2020 12:04 pm

Yes, there are some gotchas for the superstol...

Richard has made an awesome kit with really good instructions for the highlander, Mine was the Prototype for the Superstol.

So there are some differences, that will make the kits different.

The former he makes is the heart of the system, and the angle of the former at the top of the firewall is different between highlander and Superstol.

The Lexan should be left longer around the edges than the Highlander template as well.

These are the major things, call me before you start cutting.
Shawn
907-394-9344
SuperStol XL With Titan 340
#486 - N331AK
Shawn Taplin
Mods in progress: Wing extensions, Airfoil tail ribs
Goal: 15mph no wind
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Re: Extreme Windshield

Postby SheepdogRD » Mon Mar 02, 2020 10:47 am

BDA wrote:The former he makes is the heart of the system, and the angle of the former at the top of the firewall is different between highlander and Superstol.

The slight angle difference means the former must be rotated a few degrees forward from the vertical on the SS. That change is made by properly trimming the side "legs" per the revised instructions. Cosmetically -- well, it's never seen.
Mechanically, it doesn't detract. In fact, addition of the former stiffens the firewall. In the standard boot cowl installation, the firewall is unsupported above the fuselage tube; the gap between the firewall and the boot cowl is only filled with a flexible rubber seal provided in the kit. But, with the Extreme windshield, the boot cowl, windshield and former are all fastened to the firewall and the fuselage. This makes the firewall and the windshield system absolutely rock solid, and the rubber seal is eliminated.

BDA wrote:The Lexan should be left longer around the edges than the Highlander template...

This was the real "gotcha", and it's fixed. The SuperSTOL windshield bracket is 1" taller than the Highlander bracket, so we have to add material to the Lexan shape for the SS. The new SS Lexan cutting template is being added to the installation instructions.

One other change came from Shawn's recommendations: the SuperSTOL sunroof bracket system has been modified. The new system allows more width to fasten both windshield and sunroof, and makes alignment easy.

I can't thank Shawn enough for the work he did on this. He's been a good partner, and the installation on the SuperSTOL is better because he helped guide it.

Well Done, Shawn.
Richard Holtz
Highlander N570L -- Ms. Tonka -- in gestation

If just enough is really good, then too much ought to be perfect.
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Re: Extreme Windshield

Postby BDA » Mon Mar 02, 2020 5:22 pm

If you are going to do the extreme windshield, do not fit your doors until the windshield is in.

These are the voices of experience.
SuperStol XL With Titan 340
#486 - N331AK
Shawn Taplin
Mods in progress: Wing extensions, Airfoil tail ribs
Goal: 15mph no wind
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Re: Extreme Windshield

Postby Clark in AZ » Mon Mar 02, 2020 8:35 pm

BDA wrote:If you are going to do the extreme windshield, do not fit your doors until the windshield is in.

These are the voices of experience.


WHOA! That's good to know. I've got one door pieced together, I'll wait to do the other until I get the windshield done...

Thanks for posting.

Clark
Building SuperSTOL Kit 512
Cave Creek, AZ
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Re: Extreme Windshield

Postby BDA » Tue Mar 03, 2020 2:40 pm

Clark,
Its not door size, it is location of the hinges on the frame.

IF - you wrap the glass on the outside of the windshield frame as I did, it spaces the trim out which pushes the door out.

You have the option of putting the windshield inside the vertical tabs, this may be more difficult.

This is a 2 person job.
SuperStol XL With Titan 340
#486 - N331AK
Shawn Taplin
Mods in progress: Wing extensions, Airfoil tail ribs
Goal: 15mph no wind
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BDA
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Posts: 420
Joined: Mon Aug 22, 2016 11:25 am
Location: Kenai Alaska

Re: Extreme Windshield

Postby CanadianSheepHunter » Tue Apr 21, 2020 2:46 am

Shawn suggested to use Lexan to mock up the firewall...excellent idea ! Thanks
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Re: Extreme Windshield

Postby Clark in AZ » Tue Apr 21, 2020 10:45 am

Great idea! That should take all the guess work out of it...

Clark
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Re: Extreme Windshield

Postby CanadianSheepHunter » Tue Apr 21, 2020 11:31 pm

Ready to trim the Lexan. The fibreglass former is tilted forward so the front face of it is flat against the Lexan(firewall). The former will be trimmed down lower so that the front face top edge of former will match my black line on the Lexan. Once the former is trimmer lower the sides of former will then match up on the sides where you currently see a gap between the lower edge of side of former and metal.
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Black line drawn onto the Lexan from the paper template I printed, the fibreglass former face will be trimmed down until the front top face of former is same height as the black line
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Re: Extreme Windshield

Postby CanadianSheepHunter » Wed Apr 22, 2020 12:03 am

Lexan trimmed as per paper template, now to trim the former so that the front face matches the Lexan.
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Lexan trimmed with vibration oscillating tool
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