Forming the lower windshield edges to the cowling.

[Ebby]

I saw an video clip showing how to form the flange on an aluminum rib lightening hole using a section of dowel with a slot cut in the end to bend the edge of the hole. I was wondering if a similar method would work on the lower edge of the windshields where they meet the cowling. I looked through the archives and Eric Livios CD and didnt find a specific reference on how to form the edge. Having taken a long time to make and shape the windshields I don't want to mess up the edge formation. How this important step is done?


Ready to copy...

[splischke]

I wish I took more pictures of the forming process because it's so hard to describe in words. But basically I used wood form blocks, some flat and some rounded, to gently hammer the lower frame to shape. One wood form was a broomstick handle! Another "tool" I used a lot was a piece of wood about 3" wide and 6" long with a thin slot cut 3/4" or so deep into the end. The slot slipped over the aluminum edge to help make the bend. The forming process is tedious and time-consuming the first time but gets faster and easier on the second windshield.

-Scott

[Ebby]

Yours look great. I have a piece of aluminum left over and will practice your the technique. It always seems a hint or two is needed to start a new skill. Thanks. Other ideas are also welcome.

[Jackal]

What material did you use for the w/shield frame. My plans are a CB-1 and don't include such.

I'm thinking the alloy might be key to making those nice forms.

[splischke]

I used 0.032" 3003H-14 for the frames.

-Scott

[splischke]

I should mention that despite using soft aluminum, I still had to anneal the corners of the frame several times as it got work hardened.

-Scott

[Jackal]

Thanks