Making new side windows
 

In the crash and rebuild forum, I've outlined a rebuild of a Hanger 9 Taylorcraft. It had the entire front end destroyed including windscreen and side windows (six). Parts are no longer available for the plane and I wanted to expand the framework slightly any way to gain some strength so the windows were resized a bit. Today, I experimented with making the windows and found it quite easy to do. No doubt this has been covered in the past but I've not seen it so will outline how it was done.

I used a large oval discarded crock pot oven kept for warming an engine to replace bearings. Needed will be a female mold to match the size of the opening and thickness. The male mold also must match the thickness and be 1/16 smaller around.

Step 1- lay down a piece of wax paper to keep the polyethylene from sticking to the oven if it overheats a little.
Step 2- lay the male mold in the oven.
Step 3- lay a piece of 15 thousandths sheeting on the male mold cut at least 1/2 inch oversize around.
Step 4- lay the female mold over the sheeting and align equal spacing around the male mold.
Step 5- lay a scrap piece of plywood on top of the female mold
Step 6- lay a weight on top of the plywood
Step 7- turn on oven, cover and watch. Mine took less than ten minutes and the weight drove the female mold over the male mold and bottomed.
Step 8- turn off oven and let cool.
Step 9- remove, trim lip to about 1/4 inch for glazing into model after covering. Window sits flush to outside and glazes inside.

I have such a hard time with this web site requiring multiple attempts at everything that I won't upload pics here but they are available on a rebuild page for the Taylorcraft. The making of the windows is at the end of that page.

http://pages.suddenlink.net/arlyn/tcrebuild.html

RE: Making new side windows
 

Thanks for posting your link. The information is of real value to me.

RE: Making new side windows
 

Yep thank you much. I have a Musketeer that I got from a friend. It is missing windows. Now side windows easy enough , please show how you do the front windshield . I will need to make one almost like yours.
Thanks.

RE: Making new side windows
 

I've never made a front windscreen for other than an open cockpit model. The one being used in the rebuild of the Taylorcraft is the one for the current version that is narrower but works because a total front end rebuild allowed making the change. Fiberglass Specialties offers a windscreen and cowl for the older version but that meant painting the cowl so I took a chance and went with the newer model parts and fortunately they worked out.

If you need a windscreen, check with Fiberglass Specialties.

Someone smarter than me will have to point to how to make a windscreen.

RE: Making new side windows
 

where did you get the poly sheet from?

RE: Making new side windows
 

Local hobby shop had it. K&S Engineering, stock #1304, (773) 586-8503, www.ksmetals.com

The LHS had it in both .015 and .030. I did not try the process with the thicker. I'd think the extra weight of the thicker wouldn't be wanted for side windows.

btw, the process could be done in the kitchen oven just as well.