Windshield question

[Cessna4542c]

 I search the archives for information on windshields but could not find what I was looking for. I’m just wondering if it is better to wrap the front with
Lexan or something similar or could I just cut three individual pieces of plexiglass and fasten them in between the braces?  It doesn’t take much to weld in some fasteners to hold individual pieces. I was just wondering if anybody has done it this way.

[MrG]

I wrapped mine - easy job its easy to get off for maintenance 
i put nutserts for the screws to go into 

[Hugh Sistrunk]

I used Lexan on mine - welded tabs to the windscreen frame for through bolts - put sides on first - then front over them - Lexan bends can be done in standard metal brake with out any problems or heating.  Hope this helps
Tried to send 3 pics, then 1 pic - files too big it says - send me your email and I will send pics that may help.
Hugh
NightEagle

[Hugh Sistrunk]

Never mind the email address, it looks like the pic snuck thru somehow.
Hugh

[Cessna4542c]

Looks great. It looks like you been the front piece over the side pieces. What did you cut it with?

[Hugh Sistrunk]

Yes, I bent the two sides of the front piece over the side pieces to keep the wind from getting under the corners - that has worked so far.  I used Lexan because it bends in a sheet metal brake without breaking (up to a point :-) that is) - It is a bit softer than plexiglass, so will scratch or haze easier than plexi, so is important to flood with water to clean - just a damp rag will cause scratches if you dont get all the grit off first when cleaning.  You can buy a Plexiglass cutter at Home Depot or Lowes - but I just use my Lock Blade knife upside down to scribe the line several times where I want to 'break' the lexan or plexi - I use the tip of the top of the blade to scribe the cut line several times, place that line along the edge of the work bench, with the piece I want to keep on top of the bench and snap down along the line.  Use scrap to practice a few times and you will have it down.  Hint:  Keeping the protective film on will help deter scratches while doing the cutting.   Hope this helps
Hugh
NightEagle

[MrG]

i make a of templates with lexan 
we use a thin 4" cutoff wheel , or tin snips (just dont cut to end of snips) you then can sand it with flap wheel
make sure its at temp if its too cold it can crack , never had a crack when cut with grinder

I always add some 2" electrical tap to the bend line on both side as the plastic can pull away and you can get scratches
you are more likely t break it drilling a hole with a new sharp drill bit

[Vince Carucci]

What size sheet did you purchase? 
AC Spruce has a .060 - 4' x 4' for about $30. 
Does that sound about right?

Vince

[Cessna4542c]

Hi Hugh,

 Can you tell me what the thickness was of the Lexan you used?

[MrG]

i thing i did find you must use grommets and a washer  and do not do the screws up tight
the lexan with craze a little at the holes

[Hugh Sistrunk]

Thickness of Lexan Used  - What ever they had at Home Depot - I think it was 3/32 inch....

[Cessna4542c]

 I wanted to thank you all for the input. I think I will cut out cardboard templates and then trace them and cut out the Lexan. I’ll have to put a few more fastener tabs on the windshield braces but I prefer this method instead of heating the Lexon up and bending it around the windshield brace. I looked at 060 thickness and I think that’s too thin.  I think I will put on a little heavier thickness.