Project: BuckRV-8     -     Entry

Dec 04, 2023 4.75 New windshield trimming and fitting Category: Windshield
Began the installation of the new (second) windshield, after deciding the first one had too big of a gap at the rear lower corners:

1. Set the old windshield on the airplane and noted the additional height that would be needed at the rear lower corners.
2. Clamped the old windshield on top of the new one and marked a cut line with a fine Sharpie marker. Added the desired additional amounts.
3. Cut the new windshield to a rough size using a Dremel tool, then smoothed the edges a bit with a handheld belt sander and some sanding blocks, just so I could handle the windshield without stressing it.
4. Place the new windshield in position and marked where it needed to be trimmed (mostly at the top edge) and beveled it.
5. Made a first pass of trimming and sanding, then checked the fit again. I think one more short session of trimming will get it perfect. The windshield already fits very nicely, and although I probably could have made the first one work OK, I'm happy I decided to do this particular project over.


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