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  #21  
Old 04-12-2021, 07:44 PM
mburch's Avatar
mburch mburch is offline
 
Join Date: Feb 2005
Location: Oregon
Posts: 1,316
Default

Quote:
Originally Posted by painless View Post
I did the same thing. Completed in 2006 and looks like the day I installed it.
Looks great Jeff. I assume you sealed it up with proseal or similar?
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  #22  
Old 04-12-2021, 10:48 PM
painless painless is offline
 
Join Date: Jan 2005
Location: Peshtigo, Wisconsin
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Quote:
Originally Posted by mburch View Post
Looks great Jeff. I assume you sealed it up with proseal or similar?
Thanks. Yes, sealed with proseal.
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Jeff Orear
RV6A N782P
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  #23  
Old 04-13-2021, 02:25 AM
JRichichi JRichichi is offline
 
Join Date: Mar 2013
Location: League City, TX
Posts: 105
Default One piece??

I'm curious. Has anyone ever made this as a "one-piece" part? Is it too difficult to get to fit? Just wondering.

Thanks!

Jeff
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  #24  
Old 04-13-2021, 08:24 AM
painless painless is offline
 
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Location: Peshtigo, Wisconsin
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Quote:
Originally Posted by JRichichi View Post
I'm curious. Has anyone ever made this as a "one-piece" part? Is it too difficult to get to fit? Just wondering.

Thanks!

Jeff
In the right hands, with the right tools and with some experience Iím sure itís possible. This weekend warrior could only get it to work in two pieces.
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  #25  
Old 04-13-2021, 08:53 AM
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mburch mburch is offline
 
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Quote:
Originally Posted by JRichichi View Post
I'm curious. Has anyone ever made this as a "one-piece" part? Is it too difficult to get to fit? Just wondering.
It's certainly possible, but it would be way more work. It's not a matter of just doubling the size of the bending jig - you'd have to design a much more elaborate one entirely. Or if you were the manufacturer of the airplane kit and you had access to the 3D files needed to fabricate a factory tool, you could spent many thousands to build yourself a fixture you could use to stamp them out by the dozen. Me, I'm happy with the two-piece solution!
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  #26  
Old 04-13-2021, 09:01 AM
JRichichi JRichichi is offline
 
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Location: League City, TX
Posts: 105
Default Two pieces makes sense

Thanks for the replies on the "one-piece" version. Yeah, I can see how making a one-piece aluminum windshield fairing could quickly become a nightmare. Everything would have to be perfect to work. The two-piece version would allow for small adjustments to get it to fit. Thanks for the comments!!

Jeff
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  #27  
Old 04-13-2021, 09:41 AM
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I should also point out that a three-piece fairing is certainly possible: a mostly-straight piece across the middle, with a curved piece on each side. I recall that the RV-14A prototype was built this way.

Mine will probably end up being quasi three-piece, as I'll likely make a small splice plate out of .020" to dress up the joint between the two halves. Once it's painted you'll never see it.
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  #28  
Old 04-13-2021, 10:37 AM
PilotjohnS PilotjohnS is offline
 
Join Date: Jan 2016
Location: Southwest
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Default Wow

Quote:
Originally Posted by painless View Post
I did the same thing. Completed in 2006 and looks like the day I installed it.
Wow, I hate you guys. Well not really. Here I was all set to do some fiberglass work, but I think I like this a lot better. I think I might try this. Both these fairings came out really nice; I think i can do that too!

My plan is to Sikaflex the windscreen on, than make this fairing out of metal. if it doesn't work, I will fiberglass.
A really big thanks for posting
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Last edited by PilotjohnS : 04-13-2021 at 10:39 AM.
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  #29  
Old 04-13-2021, 11:09 AM
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wirejock wirejock is offline
 
Join Date: Oct 2005
Location: Estes Park, CO
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Default One piece windshield trim

I envy that kind of skill. Beautiful work.
Since I lack the skill and the patience to learn it, I made a one piece fiberglass trim. Reason is, if for any reason the windshield has to be replaced, both can be removed just like an auto windshield. Bonded with Sika.
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Larry Larson
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wirejock at yahoo dot com
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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  #30  
Old 04-13-2021, 01:15 PM
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Jim Ellis Jim Ellis is offline
 
Join Date: Jul 2006
Location: Flower Mound, Texas
Posts: 135
Default Bad Influence

I'm afraid I may have been the one who got Matt started down this road way back in 2015.

I had good success making metal fairings by following the method described in the 27 Years of the RV-ator, "Aluminum Windscreen Fairing". No English wheel needed (even though I have one in the shop).

The only trick is measuring exactly the angle between the upper deck and the windscreen every two inches and bending the lower fairing flange to exactly those same angles.









The lower fairing is made from 2 pieces of 12" x 36" .025" 2024-T3 alclad. The upper fairing is made from one piece of 12" x 72" .032" 2024-T3 alclad.

Both fairings are bonded to the windscreen with Sikaflex-295i UV adhesive.
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Last edited by Jim Ellis : 04-13-2021 at 01:24 PM.
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