(20) Windshield and other Windows (Mike)

(20) Windshield and other Windows (Mike)

Postby planecrazzzy » Tue Dec 07, 2010 8:45 pm

Hey Guys,
I used a jig to hold the tabs flush with the tubes...
Attachments
Tab Jig 005.jpg
Tab Jig 007.jpg
Tab Jig 009.jpg
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
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planecrazzzy
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Re: Windshield

Postby planecrazzzy » Tue Dec 07, 2010 8:51 pm

The windshield holes needed to be tapered to have flush screws...

The best counter sinking tool was the one with multiple flutes... The single one wanted to cut/dig too much...
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Attachments
Windshield 001.jpg
Windshield 007.jpg
Windshield 009.jpg
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
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planecrazzzy
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Re: Windshield

Postby planecrazzzy » Tue Dec 07, 2010 8:57 pm

The Acrylic plastic was used because it's what "Jim Clement" uses on his Tailwinds...
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Thickness is ".118 " , almost 1/8"
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After it was screwed down completely... it was marked , and the excess was trimmed off...
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Gotta Fly...
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Attachments
Windshield 010.jpg
Windshield 011.jpg
In this picture , notice the "Overlap" the windshield has on the rear tube... it will overlap the fabric a couple inches
The tabs were put to the rear... This should help keep the weather out
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
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planecrazzzy
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Re: Windshield

Postby planecrazzzy » Tue Dec 07, 2010 9:05 pm

Next step was to make trim pieces... These would go on each side... They hold the side window in place....

and the trim will continue to the full length of the windshield , overhang for the gap seal to attach to...( Later )

The trim piece is held on with every "other" windshield screw...

The aluminum was Flaired/Dimpled , and it fit fine...
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The side window was needed "in place" .... in order to get a nice tight fit against it... ( no screws there )
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Gotta Fly...
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Attachments
Windshield 012.jpg
Windshield 015.jpg
Windshield 018.jpg
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
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planecrazzzy
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Location: Minnesota

Re: Windshield

Postby planecrazzzy » Tue Dec 07, 2010 9:13 pm

The Center post.... I modified mine.... I didn't like putting sheet metal screws in such a thin wall tube...

So I welded " threaded inserts" in the tube....

Here's some pictures...
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Gotta Fly...
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Attachments
Tab Jig 012.jpg
Tab Jig 014.jpg
Tab Jig 015.jpg
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
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planecrazzzy
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Re: Windshield and other Windows

Postby planecrazzzy » Sat Dec 18, 2010 11:05 am

The Door windows were cut... The first one fit good.... But the second one fit GREAT....

After all the windows were finished , I had enough material to cut another door window ....

Now both side fit very good...

To secure these later , I thought about using flush rivets...

I priced some "Flush Pop Rivets" from a local Company ( Stainless )

Holy Cow... They said 21 cents EACH...

I was surprised that ACS was CHEAPER.... But they are 14 cents each....

Still too Rich for my Blood....

I thought .... Why can't I RE shape a regular Stainless Rivet ????

I was so shocked how GOOD my first one turned out....

I had to double check to see if I accidentally had grabbed the Stock Flush Rivet...

HA !!!!!!!!!!!!! To my surprise , these things are EASY to change....

That means "my" flush pop rivets are about 2 cents each....
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Here's how it's done....

In a plate of Cold Rolled steel.... I drilled an 1/8" hole for the rivet to sit in....

I countersunk the hole , to give the rivet "head" room to move....

I drilled out a piece of Mild steel Round Stock....

It slips over the other part of the rivet... ( Stem ??? )

I got things into position.... Gave it a light tap... Wala...

Instant Flush pop rivet....
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Gotta Fly...
Mike & "Jaz" in MN
Attachments
Flat Rivet Maker 002.jpg
In this picture... The "STOCK" flush rivet is the one on the Bottom
Flat Rivet Maker 001.jpg
In this picture ... The "STOCK" flush rivet is on the left
Window 001.jpg
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
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planecrazzzy
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Re: Windshield and other Windows

Postby planecrazzzy » Sat Dec 18, 2010 11:10 am

Hey Guys,
I got the tool finished...

All I really needed to do was make the bottom part...

I ended up using the same round stock as the top piece...

I put two flat spots in it for the Vise....

I'm ready to use it now...
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Here's some finished pictures...
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Gotta Fly...
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Attachments
Flat Rivet Maker 003.jpg
Flat Rivet Maker 004.jpg
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
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planecrazzzy
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Posts: 758
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Location: Minnesota

Re: Windshield and other Windows

Postby planecrazzzy » Sat Dec 18, 2010 11:28 am

Hey Guys,
I'm adding side windows to my Buttercup... The way my seats "sit"... I really need them...

At First , I planned to use a sheet of .032 , and put three tabs on the door post ...

I was going to fasten it with flush screws , and use fabric to secure it... That was going to be the tricky

part ... Fabric can pull very good... So I was going to need the window "in place" to keep this

frame from warping.... After getting several pictures from Tailwind guys , showing me examples of their side

window installation , I decided to form some angles , and beef it up...

I made the angles out of .032 material , and welded the frame for added strength...

Here's some pictures at the beginning...
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Gotta Fly...
.
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Attachments
Window 004.jpg
Window 005.jpg
Window 007.jpg
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
User avatar
planecrazzzy
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Posts: 758
Joined: Sat Jan 01, 2005 1:23 pm
Location: Minnesota

Re: Windshield and other Windows

Postby planecrazzzy » Sat Dec 18, 2010 11:37 am

Next , I drilled the assembly in a staggered pattern... and use some of those soft rivets...

tiny little things I used to hold the spinner nuts in place.... ( I had to buy a volume of them )

I countersunk the holes.... put a little rivet in , and tapped it with a ball peen hammer until

it looked good... and they are holding the frame together making it pretty ridged ...
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You can see in these views how the side windows will be VERY handy... look at the seat position...
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. Gotta Fly...
,
Attachments
Window 008.jpg
Window 010.jpg
Window 011.jpg
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
User avatar
planecrazzzy
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Posts: 758
Joined: Sat Jan 01, 2005 1:23 pm
Location: Minnesota

Re: Windshield and other Windows

Postby planecrazzzy » Sat Dec 18, 2010 11:42 am

mo pix
Attachments
Window 012.jpg
Window 013.jpg
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
User avatar
planecrazzzy
Site Admin
 
Posts: 758
Joined: Sat Jan 01, 2005 1:23 pm
Location: Minnesota

Re: Windshield and other Windows

Postby planecrazzzy » Fri Dec 31, 2010 9:50 pm

Now to make the tiny angles that hold the plastic in place... My three in one tool will only bend a minimum of 1/2 inch

So , the way I got the one leg of the angle so small.... I bent the piece of aluminum... I turned the flange down...

and slid the aluminum into the shear.... pulled it tight... made some measurement marks and pushed it in 1/4 inch... Cut...

Wala , nice little angle... I made all the inside angles , bought some small screws and nuts... ( later I'll find nylocks )

Here's the window held in place with the angles...

this is also a good view of how much the rivets were tapped with a hammer...
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Gotta Fly...
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PS After I was done with all of this , and the frame was in place.... I marked the longeron... and added a tab to hold the back area...

I put a flush screw in it , just like the other three holding it at the door post....

One more note , this will be covered with fabric , the plastic doesn't need to be in place.... it's strong
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I'm doing the fabric now 11/2014... I was worried about the frame with the window "out"... It held !!!
another thing I just read... I made those angles before I made a "MOD" for my Brake...
Now... I can bend material that small...
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Attachments
Window 014.jpg
Window 015.jpg
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
User avatar
planecrazzzy
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Posts: 758
Joined: Sat Jan 01, 2005 1:23 pm
Location: Minnesota

Re: (20) Windshield and other Windows (Mike)

Postby planecrazzzy » Fri Feb 10, 2017 9:09 pm

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Windows With Loctite and lock washers
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Gotta Fly...
Attachments
2017 (20).JPG
2017 (19).JPG
Sometimes you just have to take the leap
and build your wings on the way down...
                Gotta Fly...
User avatar
planecrazzzy
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Posts: 758
Joined: Sat Jan 01, 2005 1:23 pm
Location: Minnesota


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