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Thread: Cracked windshield

  1. #11
    Senior Member
    Join Date
    Mar 2009
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    Pittsboro,NC
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    299

    Default Re: Cracked windshield

    I e-mailed LP about my windshield cracking, explained how it happened, didn't ask for anything except advise on repairs. That was on July 12 and as of the 17th I have had no response. I'm a little disapointed that they didn't answer a simple question from a customer. I'll let ya'll know if I do hear from them but I don't expect to after this long. Thanks, James Thomas

  2. #12

    Join Date
    Jul 2009
    Location
    Adelaide Australia
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    5

    Default Re: Cracked windshield

    My first Kitfox was supplied with 1/8" Lexan for the windscreen. 1/8" is quite thick and won't cave in at speed (+110mph) Earlier models were supplied with 0.93" and this would. Only problem I found with Lexan is that it tends to crack near the Butt rib curve after time and also, if you spill gas onto it on a hot day it instantly crazes. I have replaced a few over the years because of this. A 4ft x 8ft sheet of lexan will actually make two complete windscreens if you plan out the sheet. On my latest fox I installed the LP Aero windscreen and I love it so far.

    Gary Algate (Classic 4 Jab2200)

  3. #13

    Join Date
    Jul 2009
    Location
    Adelaide Australia
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    5

    Default Re: Cracked windshield

    Unfortunately when I spilled gas on mine the lexan actually cracked (looked like a shattered windscreen) and had to be replaced. Funny thing was that it only cracked if it happened in the middle of summer, never in cooler months. (I lived in N.Ontario at the time)

    Gary

  4. #14

    Join Date
    Jul 2009
    Location
    Adelaide Australia
    Posts
    5

    Default Re: Cracked windshield

    This makes sense. On my first plane I had the 582 and had a filler on my panel tank as well as the wing. It was when filling the panel tank that I managed to splash the windscreen. I became reaaly good at changing windscreens and on one occasion, cut and fitted one in less than 2 hrs. (we had a funfly that day).

    Anyway after the third one I removed the filler spout on the panel tank and only filled thru the wing.

    I was really popular among the Kitfox group around Sudbury as my windscreen fitting talent was often called upon!

    Gary

  5. #15

    Join Date
    Jul 2009
    Location
    Adelaide Australia
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    5

    Default Re: Cracked windshield

    I always used a Jig saw with a fine metal blade. After marking out the pattern (using old windscreen) I would then stick masking tape each side of the line to prevent the motion of the jigsaw plate from marking the lexan. It cuts like butter and I have never had a problem.

    Always do this in a reasonably warm environment (sunny day or heated garage). I have seen lexan crack when cutting on a really cold day.

    Re Riveting - yes no problem just make sure you use soft Aluminum rivets (Hard rivets pull too much and will crack the lexan) and overdrill the rivet holes in the lexan by at least 1/3rd to allow for expansion.

    Sand all edges to remove sharp edges and stress points.

  6. #16

    Join Date
    May 2009
    Location
    ca
    Posts
    7

    Default Re: Cracked windshield

    The plastic shop from which I bought my 4x8 piece of Lexan for my model 3 also stocked and sold me a saber saw blade specifically for thin plastic.

  7. #17
    megawatt's Avatar
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    Aug 2009
    Location
    Loveland, Ohio
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    22

    Default Re: Cracked windshield

    Question? Can anyone tell me how to repair, install a new windshield that has a 3 inch chunk out of the left corner? Thanks, Dave

  8. #18
    Super Moderator Mark's Avatar
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    Jun 2008
    Location
    Boise, ID
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    111

    Default Re: Cracked windshield

    Dave,
    Is the piece out of the front or rear? I had a 1 1/2" piece break off near the front corner and repaired it with super glue gel. It (fortunately) is consealed behind the boot cowl but it is still holding after 150 hours. Does your broken piece have a screw hole in it? That might help support a glue bond.
    Good luck,
    Mark & Renee Smith
    Boise, ID
    "Build It ..."

  9. #19
    megawatt's Avatar
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    Aug 2009
    Location
    Loveland, Ohio
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    22

    Default Re: Cracked windshield

    Mark, The piece is the corner above the pilots head. It measures 5 inches into the top edge and 3 inches down the side edge, with a shallow arc between the two points. The guy I bought it from said he had been told it was still a usable windshield, but I have my doubts. I just got the fuselage and have not had time to look into the coverage of the windshield once installed. Thanks, Dave

  10. #20
    Spook712's Avatar
    Join Date
    Sep 2009
    Location
    Noervenich, Germany
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    139

    Default Re: Cracked windshield

    Hey Guys,

    i'm Marc from Germany.
    Since i'm not in the states, getting spare parts is pretty expensive.

    My Windscreen on my 4 Spaeedster just crackes and i'm afraid I can't glue it.
    It was a Tinted acrylic one.

    Some questions:
    What company is LP that is reffered to at some places in the thread.

    How can I manufacture a lexan one, can I bend and form it without heat?

    Is there an alternative for the preformed one from Skystar ??

    Thamx for the help,

    Marc

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