Aluminum Windscreen Fairings
 

I really like the method of using a aluminum fairing strip to attach the windscreen rather than the usual way of fiber-glassing the screen permanently in place. On my last (factory) plane it was a snap to replace the windscreen. ;)
I purchased the instructional DVD and RV-6 template from M.L.Skunkworks on how to make your own aluminum fairings at home right there in your own shop. I know honest customer service is at the top of their list cause it says it right there on their home page but they forget to tell you one little important item in their advertisement. You need about three hundred bucks worth on specialized tools to acheive the results. :eek: I started to watch the DVD and within a few minutes out comes the Lancaster Porto-Metal metal stretcher/shrink-er. $239.00 plus shipping from ACS. Then comes a Joggle tool, about 40 buck+S&H also from ACS.
It's probably just me but don't you think they should have mentioned those needed tools in their add. :mad:
I have all the sheet metal tools needed for the RV then some but until I saw the DVD I didn't even know the Porto-Metal existed. :confused: Tried looking on EBay and other sites for a used one but couldn't even find a listing.
At least NOW I know why all you guys glassed your windscreens on. :rolleyes:
They say you only learn by mistakes so I'll bet I'm going to be one smart S.O.B. but the time I get this thing flying. :D

Metal forming
 

When you have the Porto-Metal mastered you should consider an english wheel. Then you can whip up some wingtips and a cowl. :D

John Clark ATP, CFI
FAA FAAST Team Member
EAA Flight Advisor
RV8 N18U "Sunshine"
KSBA

HAHAHAHA "whip up" HAHAHAHA :D

No Special Tools Needed
 

Tom, I also wanted the aluminum and had a friend that had already done it. I simply cut out a cardboard templet that fit. worked the pieces carefully then drilled and clecoed in place. The only forming was done by hand and was very minimal. It seemed to be much easier than what others have gone thru with glass! See Here post #85 http://www.vansairforce.com/communit...?t=1511&page=9

I too made the windscreen fairing and canopy rollover fairing from metal ( RV 6 slider ). No special tools are required. There is an article in the June 97 RVator on how to go about doing this with no more than a wooden former block and a simple hand roller tool. It worked a treat. I drilled and screwed the lower fairing to the windscreen....If I had my time again I would not do this, it doesn't need it and your just asking for cracks. I would probably use Sika instead.
Here are a couple of pics complete with " I'm not to sure" little helpers...




Good luck

[quote=airtractor8;544182]I too made the windscreen fairing and canopy rollover fairing from metal ( RV 6 slider ). No special tools are required. There is an article in the June 97 RVator on how to go about doing this with no more than a wooden former block and a simple hand roller tool. It worked a treat. I drilled and screwed the lower fairing to the windscreen....If I had my time again I would not do this, it doesn't need it and your just asking for cracks. I would probably use Sika instead.
Here are a couple of pics complete with " I'm not to sure" little helpers...

Thanks for posting! I have been trying to figure out how to do this! Any chance someone can post the article refered to?

[quote=randyintejas;544188]You can also find the article in the 24 years of the RVator book on page 133
Just trying to find the 97 RVator now. Will post it if I can find it

Here is a link to the three page article that I scanned. There is also an article on rear canopy skirts for sliders as well. https://picasaweb.google.com/1054628...OrUkIa2g-KjJA#

THANKS Airtractor!
 

Many thanks for the article images! I have the 24 years book, but it has been edited to remove some of the pictures that are included in your copy (assumed original RVAtor). When reading your copy, the method finally "clicked" in my head. I didn't get it from the 24 years copy. Really thanks. I'm in your debt. My canopy has been sitting to the side, all complete except for this feature and I had recently "given up" on the aluminum piece and was preparing to glass it. Not and more baby! Pass me the snips!

Your very welcome :) You should be able to fab it and fit it in a day.
Good luck
Regards
Graham