11/12/2006
I started the plexiglass lenses today. These things are WAY oversized, and need to be cut, trimmed, and filed down to size to fit well. Here's how they come from Van's...one piece-
Then I cut the half bubble in two halves, and set them on the tips for marking.
After spending like what seemed hours of filing, I finally got them to the point of fitting nicely. Here, you can see I've also drilled the holes for the screws that will attach these in the corners. I also countersunk the screw holes for the tinnerman washers.
I took the lenses off to drill the holes for the platenuts, countersunk for the rivet holes, and riveted the platenuts on.
Next, I checked the fit with the screws in place...
They fit slightly loose, which is what I wanted because I also put a layer of weather stripping around the lens. I used 3/16" thick weather stripping, but trimmed it down to about an eighth of an inch or so.
I took a short break to grab a bite to eat, and visit with my wife while she was home for a few minutes between training sessions. When she left, I went back out to mask off the lenses for painting around the edges. This will cover the ugly weather stripping, fiberglass lip, and the AL back plate.
4.5 hours