The final bit of business is to make the fairings for the sides of the windshield where they meet the side windows. I like the Avipro factory ones with a little channel formed in it for the side window frame cover to fit in. This makes a nice, smooth transition from the windshield to the side window. I will also make these in a "U" shape to allow them to cover the wires and fuel lines that run along the tubes on each side of the windshield area.
The side pieces were made from the 3003 aluminum sheet. I started by
rolling a 1/8" deep channel 2" in from the side:
With the channel formed, the first 90 degree bend was made about 1/2" from
the channel:
Next, before making the final 90 degree bend, the piece was trimmed to allow
it to fit just above the instrument panel on the inside.
Now the final 90 degree bend can be made to form the "U". This bend was made at 1 1/4" from the first bend.
Now the piece can be trial fitted and you can do little trimming here and there, as needed to get a good fit.. The side piece is slid into place and aligned with the side window frame. The windshield and side cover piece were then match drilled to the windshield mounting tabs (previously welded on to vertical tubes) at the sides of the windshield area.
Here is the windshield side piece in position and the side window closed
against it to test the fit:
You can see what a nice, smooth transition we have from the windshield to
the side window.
Here is what the inside looks like:
As you can see, once this is painted to match the interior, it will give
a nice clean finished look that hides the fuel lines and wires.
Here is the completed windshield installation:
Now, everything will be removed, deburred and readied for primer.
Windshield Install
Completed: July 2, 2007
Total Time: 24 hours