The fitment of the windscreen is one of those daunting challenges, that if you get it wrong it's a very expensive mistake. This part has a several compound curves that require a lot of small cuts and repeated sanding, followed by test fitting, another round of small cuts/sanding, and more test fitting. Midwest Sky Sports helped me position and make the initial fitment cuts and I marked and sanded until proper fitment was achieved.
The windscreen is lined up with excess material forward and aft of the recessed area where the canopy will be glued into place.
The center line approximation is added to the top and bottom of the windscreen to help maintain alignment when taking the part on and off multiple times.
I used fine painters tape to mark the cut areas alternating cuts on the bottom then cuts on the top.
The tape also helps keep the cuts relatively straight because you can see recessed area through the material.
Each cut on the top and bottom changes the angle of the part and how it aligns to the edges on the canopy.
It is important to alternate cutting/sanding on the top and bottom to maintain the shape of the windscreen.
I used an air-powered angle grinder with a medium 2"sanding disk to lightly sand the material down to the tape line.
This process takes 2-3 hours to complete as I slowly sanded away until enough material was removed that the windscreen fits in the joggle in the fiberglass.
The top of the windscreen also needs to be sanded at an angle because the joggle in the fiberglass along the top edge is slopped at roughly a 45 degree angle.
This helps the windscreen make contact with the area to be glued in later.
I was happy with the fitment in the corners on both sides.
Looking at the front of the windscreen, the material follows the contours of the fiberglass and will blend nicely with front of the cowling.
Windscreen is fully cut and ready to be primed and glued into place.
