installing windshield

[Rex Havis]

I need some help, I'm installing a new windshield and need some information.
what points do you use to align the windshield. Does the wing openings in the windshild need to line up with the wings. Does the loops wielded to the airfarme need to be against the windshield. Does the windshield rubber molding fit into the indent on the firewall nosebowl.

[astjp2]

Re: installing windshield

Yes the wings should match up with the holes in the windshield. I had 4 windshields over the years crack because of those stupid loops. If they touch, the windshield WILL CRACK. I removed mine with a die grinder. I measure the lower part of the windshield and center it up with the fuel filler to get it close. The windshield is sandwiched between the rubber strip and it goes in the groove of the boot cowling. The aluminum strip goes on the outside. I use a die grinder with a cut off wheel that is .035 thick to make the initial cuts, and then use roll lock sanding wheels on another one to slowly remove material. Use a unibit to drill holes or the special one that looks like a spade. Acrylic can expand and contract .080" per linear foot per 50* F temperature change. Make your holes large enough to compensate. I can install one in less than 3 hours.Tim

[Mark Julicher]

Re: installing windshield

Rex,
Fun job! Take it slow and you will do fine.
It is easiest to do the alignment with the wings on because you want to try to match the curve of the windscreen to the top of the wing. As you might surmise, if you don't trim enough you get a hump in the windscreen and if you cut too deep you get a low rider.
If you have an old windscreen, use it as a template and cut your new windscreen slightly over size from the old one. Then you can sneak up on the final trimming. If you don't have an old windscreen, just lay your new plastic in place and look at where it is touching the boot cowl.

Trimming goes like this: Mark the windscreen with a crayon where it is touching the boot cowl (leave the rubber channel off to one side for now) Trim away the plexiglass where ever it is touching the boot cowl. The object is to make the windscreen sit low enough for the top to align with the wing profile and for the bottom to lie smoothly against the boot cowl. Ignore the sides for now unless they are in the way and absolutely must be trimmed to make things fit. I do heavy cutting with a Dremel tool fiber cutoff wheel and light trimming with the little Dremel drum sander.

When everything fits nicely at the top and bottom, go ahead an slip the rubber channel on the bottom and see if the fit is still OK. Final trim as required.

The sides of the windscreen are done differently on different years, but the essence is that you are trying to clamp the sides of the windscreen to the fuselage fittings. Send a photo and it will be easier to discuss how yours should be done. But at any rate, the sides are done about last, so no worries.

The top is clamped in place with an aluminum trim piece. If you don't have that it is easy to make.

[Rex Havis]

Re: installing windshield

Thanks for the help. with the information you have provided I thank I can complete the installoation. Rex

[Forrest Barber]

Re: installing windshield

slow and easy , measure twice , grind easy ; do it in hot sun if possible. the sides are not clamped, they actually were slotted so you could remove the top strip ( that is all that holds the windshield in place) , remove the sides and tip the old out and the new into place. That was back in the day when they were manufactured for an exact fit at the factory . They came out of Benton Harbor, MI . .080 .
I use the rubber grommet-screw combination that is used bye American Champion for their windshields . The whole thing can sort of float around and is not bothered much by temp change.
Still rolling, mowing, getting unstuck, burying people, cursing at the weather and watching the big build-ups over Lake Erie ; just had a tornado touch in Western PA . Why don't we make buildings like airplanes , my Taylorcraft can withstand 170 mph right onto the nose (......