Tech: How to make a windshield frame

Made this windshield frame today. Even though this is on a TravelAir biplane, the process would be the same any application. The windshield itself is 3/16" Plexiglass and was drape formed over a pattern I made to fit the fuselage.

 

First trace the outside edge of the windshield onto a piece of paper.

 

Add the width to the inside edge. In this case I used 3/4". Also add to the back edge. I used 1/4".

 

Cut out the strip and transfer it to a piece of aluminum. I used 3003, .040. Figure out your fastener spacing, drill and clecoe the strips to the inside and outside of the windshield. Since there's an inside and an outside, be sure to mark them, they'er not interchangable.

 

Insert a piece of 3/16" aluminum rod or tubing into the gap between the two strips and and work it into shape following the contour of the windshield.
The start working the strips around with a small hammer. It doesn't take long to form them around and close the gap.

 

After you're happy with the way it fits, tack weld it every few inches. Be sure to quench the tacks so you don't distort the plexiglass. After it's all tacked, remove the plexiglass and weld all the way. I made sure to get enough penetration to weld the rod to the strips.

 

Now all that's left is dressing down the welds, polish and install. Total time was about 4 hours, but some of that was ass scratching.

 

Nice post, give us more!!!!!!!!!!!!!!!

 

That was cool, thanks.

 

That was real neat. I'd never have thought of making the edging strip in two parts and welding, always assumed you have to bust your balls to bend a piece of channel to the right shape.

 

Yea, what Morrisman said! That's what makes the HAMB so great. There's always another way to skin a cat and this forum has enough creative minds to think of a different (often much more simple and practical) way of doing it.

Great post.

How do we get it to the Tech O Matic?

 

An Irishman I used to work for said "There are more ways to kill a cat than stuffing his arse with bricks."

 

Whoops no pictures

 

Pictures are worth thousands of words.

 

No pix for me, either. Gary

 

What happened to the snapshots??

 

9 years ago maybe there were pix.
I though the archives were safe though ?

 

this thread has dust on it, damn near decades worth, anyways, I guess maybe his original host is gone by now and pictures with them.

 

I checked and aerocrafstman was on yesterday .
So maybe just maybe we can get him to reload the pictures.
Pretty please

 

Here are the pictures. I couldn't edit the original posts to insert them, so you guys will just have to figure it out.....













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Thank you very very much !