- Cut the extra material off the aft end of the windscreen. That's the area where the factory made the curved router line half way through the material, defining the arc. Not sure why they didn't just cut through the whole piece. Maybe it was to avoid corners that could be damaged in shipping.
- Set the windscreen in place again on the bow and then clamped at the forward edge and along the bow (photos #1 & #2).
- Marked all the locations to trim the material.
- Took the windscreen off & connected the dots of all my trim marks.
- Cut along my lines using the band saw. I did this by myself, with no help. It was certainly doable, but having another person to help hold all the extra material hanging off the band saw would have made it easier and more accurate.
- Used files to initially smooth out the cut edges. Then used various grades of sandpaper to finish them off (finished with 400 grit).
- Reset the windscreen on the aircraft. Photo #3 is the forward end of the windscreen after triming. Note that the material after trimming, is even with the firewall, so a clamp cannot grab the windscreen. so I used some wood shims to bridge the distance between the clamps and the windscreen.
More on the next page (same date).
Test fit, clamped in place.
Test fit, clamped at the bows.
AFTER trimming, the clamped-in-place forward edge.