After glassing in my RV-8 windshield, I removed the protective plastic from the plexiglass and found a tremendous amount of optical distortion. It is probably unsafe to fly like it is. The plexi appears to have bands of distortion similar to the patterns of wrinkles in the protective plastic.
I wonder if it is due to solvents in the primer used to finish the fiberglass. Before painting I taped down the edges of the protective plastic so nothing could seep under, then taped down a layer of masking paper. This was done on the outer and inner surfaces. I used the same process on the canopy and it has no distortion. The plexiglass is perfectly clear rather than fogged or dulled as I would expect with solvents. I thoroughly cleaned and waxed the windscreen, so the problem does not seem to be any sort of residue.
Can the windshield be saved with a process of sanding/polishing/buffing? I can just barely feel waves on the outer surface, leading me to think that they are about a few thousanths of thickness change. I can't tell if there are waves on the inside surface. Sanding on this inner concave surface might be
challenging. I would have to start with 320 or 400 sandpaper.
Is this worth trying, or is my best option to rip it out and start over?
I wonder if it is due to solvents in the primer used to finish the fiberglass. Before painting I taped down the edges of the protective plastic so nothing could seep under, then taped down a layer of masking paper. This was done on the outer and inner surfaces. I used the same process on the canopy and it has no distortion. The plexiglass is perfectly clear rather than fogged or dulled as I would expect with solvents. I thoroughly cleaned and waxed the windscreen, so the problem does not seem to be any sort of residue.
Can the windshield be saved with a process of sanding/polishing/buffing? I can just barely feel waves on the outer surface, leading me to think that they are about a few thousanths of thickness change. I can't tell if there are waves on the inside surface. Sanding on this inner concave surface might be
challenging. I would have to start with 320 or 400 sandpaper.
Is this worth trying, or is my best option to rip it out and start over?