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  #1  
Old 04-10-2021, 08:01 PM
mburch's Avatar
mburch mburch is offline
 
Join Date: Feb 2005
Location: Oregon
Posts: 1,316
Default Aluminum windscreen fairing

I decided to take a stab at making an aluminum windscreen fairing instead of using fiberglass. It's still a work in progress, but I'm very pleased with the results so far.

I generally followed the method detailed in the June 1997 RVator article, plus Andy Crabtree's thread, and figured it out as I went. Honestly I was shocked at how well it turned out - my "throwaway" test pieces ended up being nearly perfect the first time. Pretty surprising considering the kinds of three-dimensional compound bends involved. And no sanding required!

I still need to trim them to the final size and make a cover strip to go over the top of the rollbar, but that should be fairly straightforward. My plan is to blind-rivet the fairing pieces to the fuselage, and seal everything up with either Sika or proseal (probably the former, but I haven't decided yet).

Full writeup here: http://www.rv7blog.com/2021/04/10/al...creen-fairing/



















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Last edited by mburch : 04-10-2021 at 09:32 PM.
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  #2  
Old 04-10-2021, 08:41 PM
danny danny is offline
 
Join Date: Jul 2005
Location: puyallup, wa
Posts: 147
Default Nicely done.

That looks really cool....I'm jealous.
danny
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  #3  
Old 04-10-2021, 08:55 PM
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tfoster100 tfoster100 is offline
 
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Location: Dallas Ft Worth
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Default Looks Great

Very nice - I like the use of the wood for the template. Will be watching to see the final product.
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  #4  
Old 04-10-2021, 09:01 PM
spark68 spark68 is offline
 
Join Date: Apr 2013
Location: Lk Havasu City, AZ
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Default Nice Work!

Matt, That looks good, nice job.

Could you tell me what size blank you needed to make these? Maybe I have enough alum sheet around to give it a try myself.
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  #5  
Old 04-10-2021, 09:13 PM
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mburch mburch is offline
 
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Default

Quote:
Originally Posted by spark68 View Post
Could you tell me what size blank you needed to make these? Maybe I have enough alum sheet around to give it a try myself.
Good question. You need a sheet approximately 3.5' x 1' for a single half - a little less than twice that to make two, if you nest them. If you had a quarter of a 4'x8' sheet, that would probably be plenty.
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Last edited by mburch : 04-11-2021 at 09:57 AM.
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  #6  
Old 04-10-2021, 09:17 PM
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Karetaker Karetaker is offline
 
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Location: USA
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Default

Howdy Matt. Very impressed with this fairing! This is exactly what I want to try on my -7.

Can anyone tell me how I can acquire a copy of the 1997 June RVator article?

I am heading over to your blog right now Matt; thanks!
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  #7  
Old 04-10-2021, 09:20 PM
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mburch mburch is offline
 
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Quote:
Originally Posted by Karetaker View Post
Can anyone tell me how I can acquire a copy of the 1997 June RVator article?
Good news, another builder provided me with a copy, which I have hosted here for your viewing pleasure!
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  #8  
Old 04-10-2021, 09:39 PM
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Freakshow108 Freakshow108 is offline
 
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Location: Eatonville WA
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Default Fairing

Thanks for the write up. I may need to give this a try. Looks great!! What part of the northwest by the way?

Last edited by Freakshow108 : 04-10-2021 at 10:02 PM.
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  #9  
Old 04-10-2021, 10:06 PM
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Karetaker Karetaker is offline
 
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Thanks Matt!
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  #10  
Old 04-10-2021, 10:10 PM
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wirejock wirejock is offline
 
Join Date: Oct 2005
Location: Estes Park, CO
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Default Fairing

That is some impressive work.
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Donated 12/01/2021, plus a little extra.
RV-7A #73391, N511RV reserved (3,000+ hours)
Empennage, wings, fuse, finishing kit done. Working FWF
Disclaimer
I cannot be, nor will I be, held responsible if you try to do the same things I do and it does not work and/or causes you loss, injury, or even death in the process.
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