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Date:  4-15-2019
Number of Hours:  24.00
Manual Reference:  Ch 9; DWG 41
Brief Description:  Fitting the Plexiglass Windscreen

After cleaning and sanding the edges of the previous cuts on the windscreen, I repositioned the windscreen on the roll bar and fuselage then clamped/taped it in-place. It was sort of guesswork to figure out how much to trim the front of the windscreen to fit the forward fuselage skin contours. Once I conservatively trimmed the front (multiple times), I found I also had to adjust the aft edge of the windscreen to allow the windscreen aft edge to mate with the sliding canopy forward edge. There will eventually be a fiberglass molding strip that will be installed here to seal the closed canopy. I was very pleased with the fit of the windscreen. I have no gaps on any of the forward fuselage skin curvature and the gap between the plexiglass on the windscreen and sliding canopy is exactly ¼”. Next, I adjusted the height of the sliding canopy frame to perfectly match the windscreen and drilled canopy frame and roller bearings to permanently install the rollers onto the canopy frame. All the plexiglass surfaces align as I’d hoped and I’m glad to be done with the final cuts on both canopy and windscreen. Finally, I countersunk and enlarged the holes on the windscreen; and drilled & tapped the roll bar to accept 6/32 screws. I also marked the fuselage for final repainting with a flat-black finish on the dashboard.
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Final Windscreen Cut & Sand

Final Windscreen Cut & Sand

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Curvature Cuts Fit Well

Curvature Cuts Fit Well

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Roller Bearings Installed for Height

Roller Bearings Installed for Height

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