Jeff,
I just did my install, so here are a few things that I did..........First
dry fit your windshield because you will probably have to trim it to fit.
This will also give you an idea as to where you will need clamps or weigh
ts
to keep the edge in contact while the epoxy cures.
I used a black marker to trace the trim line all around the perimeter. I
called LP Aero, the windshield suppliers, and they suggested a cutoff whee
l
on a Dremel tool was OK for cuts bigger then 3/8". Further trimming shoul
d
be done with 80 grit paper in a belt sander. They frowned on orbital sand
ers
because of the sideways stress induced. You will need about a 2 mm space
between all around for windshield expansion. Once it fits well, finish it
with 150 grit paper on a wooden block to remove the 80 grit marks. This
will
prevent stress cracks later. Also round over all the edges, top and botto
m,
for the same reason.
When ready to install, I used the blue painters tape around the outside
edge of the windshield and the fuselage for clean edges. I also remarked
the
inside area and used the blue tape along those marks for a clean edge.
I then first alcohol cleaned the epoxy edges of the windshield and fuselag
e
followed by 80 grit paper to roughen the inside of the windshield where
the epoxy needs to adhere and the contact portion of the fuselage. Vacuum
,
alcohol clean again.
You will need an assistant to simply get the windshield in place so do a
dry run with the assistant using gloves. When you feel good about the
procedure, you can mix the 420 epoxy. You don't need much. Once mixed and
before
adding the flox, I used a small brush to paint some epoxy onto the edges
of
the windshield and the fuselage. I then mixed in the flox until it did no
t
run, put it into a disposable cake frosting bag and ran a bead all around
the fuselage edge. With my assistant, we placed the windshield in place,
centered it, and applied clamps and weight to insure full contact.
When I was sure all was well, I used my gloved finger to smooth the bead
inside and out. I then carefully removed the tape and was able to inspect
for
any air bubbles under the windshield. If you find any, just press then ou
t
and add a weight until set. I always covered my weight bags in clear
plastic kitchen wrap to prevent any epoxy from sticking to them.
Good luck....mine went easier than I expected and came out nice.
Mike Duane A207A
Redding, California
XS Conventional Gear
Jabiru 3300A
Sensenich R64Z N
Ground Adjustable Prop
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