January 1-6, 2017
I can see clearly now...
the windshield has windows !
Getting things accomplished with the windshield... "full steam ahead!".
Drilled the corners holes for the windows the next night. Same as the 96 other ones but took much longer having to cut those 1 1/8inch holes with a hole saw cutter; centering bit, hole saw cutter, deburr.
Next I needed to notch the back-end of the blank; on the ends where it would meet up with the fuselage, and the two areas where I would bend the piece. Started off with drilling relief holes in the corners of those cuts so that I wouldn't have a 90degree cut where it would tend to crack over time. I then cut away all the excess... followed by bending the back edge over (basically to capture the back end of the plex so that I wouldn't be seeing the raw edge of the plexi.
Followed all this up with bending the two angles on the piece by putting it in my Work-Mate (does Black and Decker even make these anymore?)... putting an aluminum "L" angle behind it to make sure that I had a perfect straight edge to bend it against. Bent both angles. (note: I should have notech the center notches about 1/2inch wider as to avoid smashing them in the "vise" of the Work-Mate) Not a problem though, just needed to pry the smashed end up a little, but... if I have to do this again I would make the cut over the outside facet about 1/2inch wider. Okay, with the windshield bent, and the capture in the back re-opened I grabbed my cutters, both left and righ-handed ones. Proceeded to rough-cut the openings for the window.
I feel pretty monotonous with writing all this like I am... I then filed and sanded the openings to the lines makig sure there were no burrs or rough edges. Standing back... it looks good. I'm happy with the results of my work.
One thing... thinking back on it now, that I would change is instead of bolting the three attachments that will connect the windshield to the fuselage (that I still need to make) I would rivet them on. As of right now, I'm going to need to put anchor nut plates in place in order to bolt them on. Unless I just say, screw the holes you won't see them... and rivet the pieces on anyway? Naaaaaa....
January 8 - 13, 2017
I'm back to WOW's !
Damn it ! I just can't let things be...
Back to making another one of these windshields. I guess if I was just trying to push through this project to have a biplane I'd say "screw it". But with the few additional things I learned from making the final one I'm saying "I can make a better one, and I'll do it now!".
- Drawing the grid again.
- Deciding on what I want to change.
- Hours of drawing up the pattern by hand, again.
- Figuring out where I want the relief holes.
And... that's pretty much where I'm at after six days of additional work.
Just made windshield sitting on pattern of newer windshield.
A few things that I changed:
- Made the width of the posts wider.
was 5/8, now 3/4
- Placed attachment holes off the corners of the glass.
- The forward bracket holes were too close to the post bend.
adjusted the spacing of those holes
- Changed the cuts in the bends in the trail-edge.
"V" instead of squared off.
- Will make trailing-edge bend after bending to shape.
- May change the glass attachment screw size.
now #8 bolt, may change to #6
January 17 - 20, 2017
We're seeing some of that...
"90 percent finished and 90 percent to go" !
The entire project is made up of "Excellence"; doing the best that we can do, above and beyond the "aircraft standard" that we need to meet. But, we need to push ourselves beyond that "the best that we can do" and do things a little better when it is sitting out there for everyone to see...
Not a lot of work on the windshield this past week. More thinking... than doing.
I decided to attach the brackets, for attaching the windshield to the fuselage, with rivets instead of screws/bolts. Cleaner look, well and it will be easier for attaching. If using screws I would then need to use anchor nut bolts which means... blah blah blah. I should have decided to do it this way the first time (what was I thinking???).
Here's where it stands so far. Still need to drill all the additional holes, then bend it to shape, then cut out the window openings then file to shape.