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Ron's Web Site
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Date: 7-30-2010
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Number of Hours: 3.00
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Manual Reference:
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Brief Description: Windshield Post
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I bent some .032 inch 2024-T3 aluminum to serve as the windshield post using the method outlined in Eric Newton's construction manual. However, I did not bend the metal around to the front, as I'd already decided to leave the wires and fuel line exposed on the interior, and instead, terminated this fairing at the middle of the vertical fuselage tube. Basically the dimensions are 2 inches, followed by a 1/8 inch depth joggle followed by a 90 deg bend followed by 11/16 inch. To make the joggle, I used a Harbor Freight beading tool, but it took a fair amount of time to figure out a way to radius the joggle dies so they wouldn't score the aluminum. Ultimately, I jury rigged a bolt passing through the die, used some spacers to center the bolt on the die, and loaded the die in a lathe, and contoured the edges using a 180 grit disc on a right angle air grinder. I really needed some 1 inch aluminum to turn down to the die inner diameter, but I didn't have any handy.
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Drilling post holes.
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Door-to-post fit.
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