Making the Windshield Lower Fairing Strip

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Bob’s Method for Installing the Windshield

Source: 1998 Beartracks, Bob Barrows

The windshield is fitted in place after the boot cowl is made and installed.



The windshield is held in place at the top by sliding into the windshield mounting (section T-T dwg. 16), by tabs which are welded to vertical T14 tubes at section B-P, and by a fairing and backup strip at the intersection of the windshield and the boot cowling.



NOTE: Do not remove the protective film from the windshield. Cut the windshield to fit the boot cowl using a 1/32″ thick 3″ diameter high speed cut off wheel mounted on an air die grinder. Do not attempt to cut the windshield to fit all at once. You should take off no more than 1/2″ inch at each pass.

After the proper fit is obtained hand sand smooth all edges of the windshield.

Windshield Fairing

The Fiberglass fairing is made up of about 8-10 layers of 4″ fiberglass tape, then trimmed to size and sanded smooth.

To make the fiberglass fairing at the bottom of the windshield, tape the windshield in its proper location and cover it and the boot cowl with black electrical tape. Cover the bottom 4″ of the windshield and the front 4″ of the boot cowl where it intersects the windshield. Add a good coat of wax to the taped area and lay up the cloth.

Some of you may be able to make this fairing out of 5052 aluminum. I hope that someone does.

As shown in the photo the fairing goes from the T14 tube around the front of the windshield and back to the T14 tube on the other side of the fuselage.



The back up strip of .032 5052 H32 aluminum is first bent about 110° on a brake, then stretched and shrunk as needed to match up with the windshield and boot cowl. Both the back up strip and the fairing are attached to the boot cowl using #6 screws about 3″ apart with nut plates on the boot cowl.

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