----[Please read http://ercoupers.com/disclaimer.htm before following any advice in this forum.]----
Subject: RE: [COUPERS] window installation Another suggestion, you may want to use Lexan in place of the plexiglass. It has a harder surface (more scratch resistant) and does not crack near as easily as Plexiglass. When cutting, use a saber saw with orbital action or the "cut" will try to weld itself back together due to the heat generated by the friction of the saw blade. A nice way to finish the edges and to help reduce the chance of cracks in the future is to "touch" the edges with the a propane torch flame. Just keep it moving and you'll see the filed edge (finished as David describes below) go from white to clear. Bending Lexan is a little more of a challenge than Plexiglass because it is MUCH tougher. You have to use heat. The upside is that you probably will not crack the Lexan when drilling or inserting rivets/screws though. >>-----Original Message----- >>From: david abrams [mailto:[EMAIL PROTECTED] >>Sent: Wednesday, October 17, 2001 7:21 AM >>To: [EMAIL PROTECTED] >>Subject: RE: [COUPERS] window installation >> >> >>----[Please read http://ercoupers.com/disclaimer.htm before >>following any advice in this forum.]---- >> >>tom woodward wrote: >>> >>> A new piece of plastic.......... about $42 >>> A sunshade with frames........about $90+ >>> The ability to do something right the first time.......PRICELESS!!! >>> >>> Any ideas? >>> 2152H >> >> >>Tom, >> >>I replaced my side windows in Sep 1998. As owner, not only are you >>allowed to replace the windows yourself, but you can manufacture your >>own parts. I signed this all off in my airplane logs using my pilot >>certificate number and the relevant FAR's referenced. >> >>I had window blanks cut to size by my local plastic dealer. >>I used the >>dimensions on the ercoupe microfilm drawing fro Bowling Green >>University. The invoice from "Plastics Etc, Inc" shows: >> >>5 pcs (I am a bit paranoid<g>) Acrylic Sheet 0.060 x 19.75 x 31.75 >> >>I paid $9.40 each blank. I used an orbital hand sander with 200 grit >>paper to round the edges of the plastic blank as shown on the drawing >> >>I reused the window hardware that was in acceptable shape, >>ordered new >>hardware for the top frames that had worn to a razor edge, >>and made new >>handles from "L" stock because the ones I ordered from Skyport were >>poorly made. I ordered a set of plexiglas drill bits from LP >>Plastics. >>I followed the Ercoupe microfilm drawings to drill the holes >>and rivet >>the frame hardware. Warning! The rivets on the sides may >>appear to be >>way far in to the middle of the window but this is to clear >>the welts. >>I used a hand compression rivet tool. >> >>It really is not too hard a job. I also replaced my rear >>windows using >>rectangular blanks of 0.060 x 18.00 x 21.00 I used a bench >>band saw and >>a fine blade to cut them to shape using the old windows as a >>pattern. I >>ordered new hardware and used Mortite as the sealing >>material. (It is a >>modeling clay type gray material used to seal windows in the winter >>around here). Be careful not to overtighten, I cracked one >>window and >>had to replace it after almost being done. I used a wallpaper seam >>sealer roller to roll down the mortite before installing the window. >> >>The flat windshield can also be made from flat stock (.100 >>from memory >>but I could be wrong) for less than $10 but you need an A&P >>to supervise >>and sign off to be legal. Note that the $10 blank cut to shape using >>the old windshield will be a much better fit than the $120 blank from >>Univair as each windshield appears to be trimmed to fit and the >>purchased blank is cut to a universal pattern. >> >>David Abrams >>http://ercoupe.com >> >> ==^================================================================ EASY UNSUBSCRIBE click here: http://topica.com/u/?aVxiLm.aVzvvT Or send an email To: [EMAIL PROTECTED] This email was sent to: [EMAIL PROTECTED] T O P I C A -- Register now to manage your mail! http://www.topica.com/partner/tag02/register ==^================================================================
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