Replacing windows

[Hendoii]

All,
I’m in the process of replacing all of the glass in my cub. When I removed the old plexi I noticed that it was a variety of different thickness after being repaired/replaced over the year. Few questions:

1. What is a correct thickness? I’ve heard horror stories of windows popping out in flight.
2. Any recommend type or brand of of plexi?
3. Any affordable places to order it from?
4. Any pointers on cutting out the D windows? Just planning on using a table saw to cut the rectangular pieces. Jigsaw for the D windows?
5. How do most people seal them in place?

Thanks in advance!


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[Oliver]

Great Lakes Aero in Michigan.
cut to size, different thickness/ tint options avail.
informative website.

 

[Hendoii]

Great Lakes Aero in Michigan.
cut to size, different thickness/ tint options avail.
informative website.

Thanks! That does look like a great option. I appreciate the pointer!


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[mike mcs repair]

Left Side slider windows are important which is on outside or they blow out in flight


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[wireweinie]

Lol! But you only have that happen once.

Web

 

[scubber]

If they leave (the side sliders) it is something one doesn't forget. One hell of a "Bang" on the left . .thought the left spar failed. The pucker factor was somewhat high. People on the ground saw it, but didn't hear it. Said all this "sparkly stuff" floated down. Sounds crazy, but at 1st I didn't realize they had left. I had used too thin plexi & didn't think I need the metal stiffeners on each end. Wrong!! Amazing that no pieces hit the tail. Larry C.

 

[cubdriver2]

Bandsaw works best, jigsaw not so good. Smooth rounded sanded edges will make them less likely to crack later.

Glenn

 

[DENNY]

I use a cutoff saw to cut mine. Then a belt and hand file to smooth off edges. drilled holes with hot acid brush shaft of nail depending on size needed. This is a good place to save weight, some cubs have very thick (heavy) acrylic in them. The thin stuff will crack much easier than the thick stuff so pick your poison.
DENNY

 

[N86250]

I am trimming a new windshield with a Dremel and 1 1/2 inch cut off disc. It is working surprisingly well for me. Lots of dust and a smooth cut. I am being very careful to not jam the disc.

 

[55-PA18A]

A band saw works well for cutting out the pieces, especially the D windows. Using a shop belt sander like this: WEN 6502 4 x 36-Inch Belt and 6-Inch Disc... does a good job of dressing the edges.

Jim

 

[Bearhawk Builder]

Last ones I cut with a Fein Multimaster tool and fine blade. Worked great!

 

[stewartb]

I used 093 plexi but my windows are big. Some guys use 080. Made templates with poster paper. Your old windows are perfect templates. Transferred those to 4x8 sheets of plexi. Used a straight board and a couple of padded clamps as a router guide. No D windows for me but if I needed I’d cut a template from scrap 3/4” plywood. Simple, fast, clean cuts with perfect edges. Once installed tape off the edges and seal with clear silicone. Smooth the silicone flat and pull the tapes.




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[Hendoii]

I used 093 plexi but my windows are big. Some guys use 080. Made templates with poster paper. Your old windows are perfect templates. Transferred those to 4x8 sheets of plexi. Used a straight board and a couple of padded clamps as a router guide. No D windows for me but if I needed I’d cut a template from scrap 3/4” plywood. Simple, fast, clean cuts with perfect edges. Once installed tape off the edges and seal with clear silicone. Smooth the silicone flat and pull the tapes.

View attachment 38257


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Thanks to everybody for the great cutting tips. I’ll let you know how it goes! BTW where do you get 4x8 sheets of plexi?


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[stewartb]

Where I live we have a couple of local plastics suppliers that sell sheets. Sometimes glass shops keep it around as well.

Most of us use acrylic (plexiglass) but some use polycarbonate (lexan). Make sure you get what you want.

 

[skywagon8a]

Thanks to everybody for the great cutting tips. I’ll let you know how it goes! BTW where do you get 4x8 sheets of plexi?

You don't say where you are located. If you are near Boston Mass go here: http://www.jfreeman.com/