Windshield to upper channel

[TLyon]

I'd also love some photos of the top of your windscreens. It's pretty obvious that the top of the windshield needs to get trimmed down as the channel might take 1" of windshield and the distance from the offset to the edge is about 1-1/2". Is there a best practice for how much needs to fit in the channel? I'm finding that I need to open it up with a hand seamer to even get 3/4" in, is that to be expected?

I want to get it test fit close enough to drill that top channel to the fuselage, but don't want to mess up a windshield forcing it in when it's so tight.

 

[Bearhawk Aircraft]

Hey Tom,
Depending on how the windshield came out of the mold, a small amount of sanding on the top windshield flange will help with the fitment a bit. I would not recommend trimming your top flange, typically the flange line on the windshield will be out of Chanel by about a 1/4- 1/2in.

 

[TLyon]

Here’s where I got to at the end of yesterday. The welds burned through a bit and warped these channels. I don’t think there’s much to be done on the aluminum at this point. If this is a workable alloy then I might be able to press something in there to straighten out the warped sections? I can work the windshield, but it will need more than light sanding.

 

[U2fletch]

Tom, just for a sanity check also measure the wing leading edge to a reference point, like the spar attachment. On the BH5 mine was exactly 13". Then I compared that number to where the windshield is sitting in the channel. Like Virgil said, there is going to be a gap in the flange. It does not butt all the way into the channel.