Name; Juliet Kuruwaa Title; Making a windshield fearing for 9G ZAF. Date 14 th of October, 2011

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1 Name; Juliet Kuruwaa Title; Making a windshield fearing for 9G ZAF. Date 14 th of October, 2011 Time 08 30am Location In front of the boat workshop Aim To make a fiber glass fearing for a windshield. Materials Equipments Participants/ roles Acetone, fiber glass, catalyst, resin, silicon sealant, A4 rivets Rags, paint brush, grinder, sand paper, spatula, greaseproof paper, cups, scissors, gloves, drilling machines, vice, wood, water, news print paper, knife, masking tape, blue pen, black marker pen, copper clicos, clico pliers, A4 rivet gun, metal rule, Mr. Porter, Miss Patricia and Mr. Tony Carinus Juliet, Emmanuella and Lydia Did the removing of the dry silicon paste from the windshield. Did the documenting, photos and did the ferrying for the windshield. Procedure: We were briefed on safety. The cockpit was inspected to be assured if the key is off and out, mags are off, throttle is back. The plane was brought from the hanger to the boat area. The engine was covered with the news print paper to avoid resin and particles falling on the engine or knives cutting the hoses on the engine. The dried silicon paste underneath and on top of the windshield was removed with a Stanley knife, ordinary knife and fingers.

2 The edges of the paper was masked with a masking tape to avoid being blown away in the wind. A dry cloth was used to wipe off the dry silicon paste on underneath the windshield In between the windshield and the metal on top of the fire wall was masked off to avoid putting resin in direct contact with the windshield..

3 The masking tape was masked around the windshield to enable us get the right seize of ferrying we needed but the tapes close to the doors were cut short in a step form to get the wide curved shape at the door sides. Another paper was wrapped on the engine to provide more security. A blue pen was used to draw an imaginary line for easy measurement of the template on the tape on the windshield. A black marker pen was used to trace the line which has been drawn with the blue pen.

4 A paper was put on the traced line and a template was cut out of it. A fiber glass mat was laid on the table and was cut according to the template of the paper. The fiber glass was cut with scissors. The fiber glass was transferred to the windshield to check if the correct seize has been cut.

5 The fiber glass was laid on the marked masking tape. It was inspected to see if the fiber glass was seated well. The resin was shook to mix evenly. Some resin was poured in a paper cup and 30 drops of catalyst was added to harden it quicker. It was stirred evenly with a spatula.

6 The resin has a time limit of about 10minutes to harden due to the catalyst put in the resin to serve as hardener. Due to that, everything was done quickly. The fiber glass was taking off and a paint brush was dipped in the resin. The resin was first spread on the masking tape with a paint brush. The spread resin stayed within the two marked line. The fiber glass was laid on the resin to enable the lower parts of the fiber glass to soak with the resin.

7 The paint brush was dipped in the resin and was spread on the fiber glass. The brush was used to beat the fiber glass to sit well and to be able to get away with the air in the fiber glass. The fiber glass with the resin was left to sit for a while. The next morning, the ferring was taken out with the tape from the windshield.

8 The remaining tape on the windshield was taken away. The edges of the firng were trimmed with snipes. The rest of the tape on the firing was removed with thinner, knife, sand paper and by finger. The firing was sand and grinded with sand paper and a grinder respectively to smoothen it and to get the profile of the windshield on the fiber glass firing. The distances between the rivets on the fire wall were taking in to consideration. A marker pen and a rule were used to measure the distances for drilling the holes. Holes were drilled with a B drill bit both in the fiber glass firng the metal sheet with the same distances to avoid drilling into an engine cable or any thing concerning the engine.

9 The holes were degreased and the marker pens on the fiber glass firing and the windshield were also decreased. The fiber glass firing and the holes in the metal sheets were held together with copper clicos. The clicos were done between one hole intervals. The marked intervals were drilled. The whole holes were cleaned after the drilling of the holes. Rubbing alcohol and drill bit were used to decrease and debarred the holes on the fiber glass firing and the metal sheet respectively. Silicone sealant glue was smeared below the windshield. A masking tape was masked at the cross section of the windshield to prevent the glue from spreading everywhere.

10 The glue was circled around the holes. The glue was put accordingly both at the ends of the left and right side of the windshield. The fiber glass was laid on the glue carefully and the holes were held again with the clicos. A4 rivets and A4 gun were used to rivet the drilled holes. A flat file was used to kiss the head of the rivets, to make it flat for the top engine cowling to sit well when tightened with screws. The glue which were sitting at the edges were wiped off with rag.

11 The engine cowling was put on with the cowling srews and was left to dry. Observation The fearing sat well on the glue and was more aerodynamic. Outcome The windshield looked secure and beautiful.