Using the aluminum template, scribe the outline on. Vs in. plexiglas, then mount the aluminum template on the airplane, securing it to the attachment tabs. 5.
Forming Of A Plexidlas Windshield By Joseph C. Long, EAA 9436 6500 Camphor St., Metairie, La.
EEDING A plexiglas windshield for my "Cloudhawk", N I used the following method for forming one without the use of a special oven or form: 1. Fabricate and install attachment tabs (6) to the top longeron of the aircraft where the rear of the windshield will be located. 2. Make a cardboard mock-up on the airplane of the desired windshield. 3. Remove the cardboaru mock-up from the airplane and make an aluminum template from .025 in. aluminum sheet. 4. Using the aluminum template, scribe the outline on Vs in. plexiglas, then mount the aluminum template on
the airplane, securing it to the attachment tabs. 5. Fabricate and install a 1 in. by .065 in. 4130 steel strap (5) and packing (4) to support the aluminum template.
1. Plexiglas
4. Packing
2. Aluminum molding 3. Packing
5. Steel strap 6. Attachment tab
8. When the plexiglas is completely pliable, form it over the aluminum template mounted on the airplane by pulling it down and holding it until it cools to the desired shape. (Grease the aluminum template with Vaseline or other suitable lubricant).
9. If the plexiglas is not completely formed on the first try, repeat steps 6, 7 and 8 until the plexiglas reaches the desired form.
10. When the plexiglas is completely formed, remove the aluminum template and install the plexiglas.
6. Form the plexiglas by holding it in front of a hot oven with the door open (kitchen oven heated to 550 deg.) until it is bendable.
11. Fabricate and install the aluminum molding (2) of the counter molding type found in hardware stores and lumber yards, and the packing (3) over the plexiglas.
7. Bend the heated plexiglas into a "U" shape and insert it into the oven for further heating.
12. The edge of the plexiglas touching the fuselage can be secured in any suitable manner. #
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