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jfrjr(at)roadrunner.com
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 Posted: Mon Jul 14, 2008 5:50 pm Post subject: windshield install question |
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Getting the windshield installed---so far, so good. But the plans ask you to make a sanding block to conform to the 7" radius between the plexi and the fuse. How does one make such a sanding block, and out of what kind of material? Thanks, Jay Rowe #40301
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n8zg(at)mchsi.com
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| Posted: Mon Jul 14, 2008 6:36 pm Post subject: windshield install question |
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Jay – I used all sorts of stuff for sanding forms at different points around the fairing on my RV-7– scrap wood blocks, chunks of PVC pipe, a coffee can, a bucket, whatever fit approximated the desired curve at a particular point.. One of the most useful was a 3M hard rubber sanding block with the paper mounted on the “wrong” side.
neal
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Getting the windshield installed---so far, so good. But the plans ask you to make a sanding block to conform to the 7" radius between the plexi and the fuse. How does one make such a sanding block, and out of what kind of material? Thanks, Jay Rowe #40301
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John Ackerman
Joined: 19 Jun 2006
Posts: 130
Location: Prescott, AZ
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| Posted: Tue Jul 15, 2008 6:26 am Post subject: windshield install question |
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Neals' "wrong side" block idea looks really good!
Deems suggested a block called Dura-Block available at the auto paint stores. It's about 1.25" in diameter and 11" long made of a hard EVA rubber foam. It's just flexible enough and it works like a charm. It gets wrapped with a whole sheet of sandpaper. I use it by moving at an angle to the direction of motion for a few strokes, then for the same number of strokes angled the other way. I use a 45 degree or so angle for rough work, and a shallower angle for fine work, depending on the curvature.
For us, the radius to be sanded was Not 7", but rather more like 3.5" to 4". There just wasn't enough glass in the schedule to make the larger radius. We did put it on as dry as we could squeegee it out between two sheets of Visqueen or similar plastic sheet.
After sanding to rough shape, I made another circle gauge out of masonite, this one of 4.5" radius, and used it to fill the radius under the front part of the windscreen with micro. The gauge was covered with packing tape to avoid sticking to the micro. It was drawn across the thick wet micro, first tilted 45 ° in the direction of motion to get a fairly even spread, then held vertically to form a well-shaped fillet. The fillet was fairly thin - I'm guessing about 1/16" in the center, going to zero at the tangent points. BTW, I tried a whole series of gauges to get the best fit. 4.5" worked well for me.
John Ackerman 40458
On Jul 14, 2008, at 7:29 PM, Neal George wrote:
[quote]Jay – I used all sorts of stuff for sanding forms at different points around the fairing on my RV-7– scrap wood blocks, chunks of PVC pipe, a coffee can, a bucket, whatever fit approximated the desired curve at a particular point.. One of the most useful was a 3M hard rubber sanding block with the paper mounted on the “wrong” side.
neal
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Getting the windshield installed---so far, so good. But the plans ask you to make a sanding block to conform to the 7" radius between the plexi and the fuse. How does one make such a sanding block, and out of what kind of material? Thanks, Jay Rowe #40301
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