Making a lexan windscreen and turtle deck

[gizmos]

Thanks for info . I raced NASCAR mini stock and dwarf car for 6 yrs. I have a vacuum forming machine to make lexan bodies for rc cars. I bought these sheets from a local glass company, these were higher quality than i normally use.we had a110 temp day when I made mine, got lucky. I had a pattern, that is the secret ! I used racket straps to help form it. I then used my heat gun for monocote covering for rc planes. I used my temp gun to make sure I did not exceed 300 degree. If you heat it to much without baking the complete sheet at 200 degrees, you can get gas bubbles. It took me about 4 hrs to work the sheet to form/ installed. The guys on this form is great! Makes life easy

[mike@waco]

Not long ago I bought a model 1 that has never been finished and I'm at the windshield turtledeck stage now. Problem is no windshield material and no pattern. Does anyone know where I could acquire a pattern to work with? I'm sure lexan can be picked up local and I've read comments on thickness that's helpful. Thanks, Mike

[HighWing]

Mike,
Since all other Kitfoxes are different when it comes to exact mounting hole location and cowl position, your first windshield will be unique. Once installed, it becomes the pattern for all subsequent windshields.


For the first install, start at the back, position and clamp the top, You can also drill and cleco to the butt ribs working forward. Cut for the front spar carry through bend then clamp against the door posts. On all rough trimming make sure to leave some excess sides and bottom because once the cowl is installed, the windshield material will have to be moved to snug up against the cowl lip. Once everything is fitting well, drill the mounting holes and do the final trimming.

[gizmos]

I made my windscreen and turtle deck cover from lexan, they turned out great. Save lots of $ if you have the time. I have a question on the gap cover between turtle deck and winf. The stock aluminum cover has two small aluminum pieces that you attach to cover. With the lexan cover , do you make them from lexan or paint the aluminum fillers and attach to lexan with rivets?

[War Eagle]

I have seen them done both ways. I have also seen them left off completely.