After
reading many other web pages and postings on how to do the front windscreen, we
choose the following procedure.
After tapping the holes in the roll bar, we used Lexcel (it doesn't craze
plexiglass and is available at ACE Hardware) as a threadlock/screw holder.
Two holes with AN509 bolts were put on the bottom sides (through the skin and
roll bar support plate).
Initially
we made two tabs to hold down the plexi while we glassed it in but the fit was
good enough not to have to use them.
A
layer of white electrical tape was put down as the final "line" for where the
fiberglass would stop. Another layer of black tape was put down over it to
as a sanding block "stop". The plexi and aluminum were sanded down to help
the resin adhere.
A
fillet of thick epoxy/micro, sanded down smooth, ensured there were no gaps
where the epoxy would pull away from either the skin or the plexi.
We
put six layers of fiberglass on the front (starting with 1" wide strips and
increasing in about 3/8" each successive layer) to make a fairing. Along
the slider/windscreen interface, we used 1-2 layers with some fiberglass mat to
take up any larger mis-matches.
To
improve the strength of the interface, we used 2 layers of carbon fiber.
We filled the front fairing with micro and sanded it down smooth. The
final coat for both sections was 2-3 applications of pure epoxy resin, sanded
down between each coating.
