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Post by einy on Apr 20, 2016 20:27:00 GMT
In Ohio, we are required to have a windshield that is 'tall enough that we have to look through - no over - it', that is made of DOT approved safety glass. I had already purchased the Exomotive offered Sport windshield frame, that offers support for the complete bottom surface of any glass, but only ~ 5" up each side. For safety glass, my guess is this would not be enough support, so I thought I'd take a shot at making a surround channel that offers full coverage for the sides and top of the glass panel.  After looking at everything available at the local Cincinnati "Metal Supermarket" (cool place, btw if you need raw material!), I settled on buying a length of 1/2" x 1" x 0.064" wall steel rectangular tube, and cutting off one side to make a "C-channel" that measures 1/2" wide x 5/8" deep. Why not just buy C-channel? While that would have been ALOT easier, it just does not seem to be available in this narrow of a width.  I cut out the sections of the channel sides where the top radii were bent, and will weld in 0.064" thick plate steel here as the fabrication progresses to restore the lost stiffness, as weld up the cutouts where I made a 5 degree inward bend from vertical on each side. I'm also going to stiffen up the top rail by Tig tacking on a 1/2" x 1/2" x 1/8" wall piece of angle iron along this run - hoping this is enough stiffness to keep the glass from caving in towards me at road speed. We'll have to see how that works out!   Here is a test fit of the frame and plywood template. Still working out exactly what the details will look like to secure this assembly to the Exomotive bottom frame, but I've got a few ideas that include a machined set of angle inserts at the bottom, and cross screws to allow for disassembly if I ever need / want to replace the glass. More to come as progress continues ! |
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Post by Trenon on Apr 20, 2016 21:26:22 GMT
Nice work, willing to share the dimensions and angle to have it sitting at?
I'm looking at a few different options right now
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Post by zeitgeist on Apr 21, 2016 0:02:55 GMT
Looking good Einy. Are you doing anything for extra support for the whole thing being pushed backwards from the top? The extra support across the top rail is a good idea for preventing bowing in and breaking of the glass but I wonder if the side mounts alone are strong enough to prevent it folding backwards.
How are the bumpers coming along?
I'll be starting the wiring harness install tomorrow so I'm still aways off.
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Post by kiwicanfly on Apr 21, 2016 0:16:25 GMT
Interesting project, securing it at the bottom is going to be a big challenge, there will be a huge wind load at speed trying to push that over.
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Post by BTD on Apr 21, 2016 3:12:10 GMT
How about adding some diagonal pillars from the top of the side channels to the main bar? Should give some help in the load department...
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Post by Trenon on Apr 21, 2016 7:06:14 GMT
Considering the FM guys put safety glass in the exomotive windshield mount that has no top support at all for the glass, never mind reinforcement, it should be ok....That being said I plan to brace mine to the main roll cage.
What do you plan to pad the glass with to protect it? I'm only going to use angle for the glass to sit up against and get the glass glued in. It's how car windshields are normally done, and will stop it from vibrating. They will cover the edge of the glass with glass trim to hid the edge and make it look OEM.
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Post by einy on Apr 21, 2016 11:02:54 GMT
Nice work, willing to share the dimensions and angle to have it sitting at? I'm looking at a few different options right now Here (from memory as I sit at work) are the various 'run' lengths:
Straight up sections (left and right) = 5" each side 5 degree angle sections (left and right) = 10" each side Radii (left and right) = 3" long each side (1.9" radius ... looked about right to me) Horizontal run = 37"
When bent like I have it how, there is 1/8" gap on each side for a 'guide plate' (1/8" thick x 5" tall x ~ 0.6" wide) that will be welded on to the outside surface of each of the straight up sections. That gives me more 'meat' to drill / tap 10-32 holes into to secure this section to the Exomotive frame (again, details still to be sorted out on this).
Hope this helps !!
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Post by einy on Apr 21, 2016 11:09:32 GMT
Looking good Einy. Are you doing anything for extra support for the whole thing being pushed backwards from the top? The extra support across the top rail is a good idea for preventing bowing in and breaking of the glass but I wonder if the side mounts alone are strong enough to prevent it folding backwards. How are the bumpers coming along? I'll be starting the wiring harness install tomorrow so I'm still aways off. Thanks ... this is really a BIG experiment to see how / if it lives given windloads at highway speed. Then again, I see similar setups on Factory Five "Roadsters", Super 7 clones, etc. I have the back rake set for now at 40 degrees hoping to ease the pressure on what - admittedly - is a big old flat section of glass. We'll have to see what happens. Main goal in the short term is to satisfy state statutes. Oh yea, I have a thumb screw type / manual operation wiper on hand now via a tip from George and a quick Amazon purchase. That is also required in OH.
On the bumper front, I am aware of one Exocet that was successfully registered in Columbus area - windshield / wiper in place, NO bumpers. So, once windshield / wiper combo is done, I'm going to send pics to that inspection office to see if they see anything that jumps out at them as a 'fail'. If they think it looks good, I'll make an appointment with that officer for an official inspection. If they say 'needs bumpers', then I need to get cracking on that.
Kind of kicking myself now on timing, as I easily could have had this windshield done up over winter. To be honest, though, after getting the bumper needed feedback from the local inspector, I was pretty burned out on the whole deal over winter and turned my free time another non-automotive direction. Motivation is back now, though so time to get on with it.
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Post by einy on Apr 21, 2016 11:13:32 GMT
Working with local glass supplier on that one once my frame welding / grinding / sanding / painting is done. They told me to bring the frame in, we'll figure it out together. I figure a rubber c-channel. For the upper frame I'm working up that'll be ~ 3/8" outside width x 1/4" inside width (that is how wide the safety glass is). the bottom (Exomotive supplied) run will be ~ 0.6" outside width x 1/4" inside width. Probably use this in conjunction with some type of RTV or silicone to fill the inevitable gaps.
More to follow as this deal progresses ... waiting on availability of my welder's time, as that is a skill I definitely do no have.
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Post by Trenon on Apr 21, 2016 16:10:21 GMT
I'm really curious what you will do for windshield wipers. I can't think of a good solution that won't look silly. We have to have powered windshield wipers here so I have to find some place for the motors.
I've half considered just temporarily attaching some to pass inspection. I doubt they will try and turn them on.
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Post by Stiggy on Apr 21, 2016 16:15:21 GMT
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Post by Trenon on Apr 21, 2016 18:18:13 GMT
I've found many different shaped motors but there's not a great place to put them. If you put them under the hood they will be visible from the passenger compartment and i'll have to cut holes for the linkage.
The other option is to mount them directly on the windshield but it will really look bad.
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Post by einy on Apr 21, 2016 22:30:57 GMT
My wiper will be top mounted, manually operated, with quick release thumb screws to hold it on ... Read into that what you will. It will be legal, however.
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Post by Trenon on Apr 22, 2016 0:39:31 GMT
i wish i could get by with manual wipers.
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Post by einy on Apr 22, 2016 10:42:56 GMT
Trenon - If I couldn't run a manual operated wiper, I'd look to use one of the cable driven units from a 60's / 70's British car (MG, Austin Healey, Jaguar, etc.). I think these all came from Lucas, with a 'remote mounted' drive motor, and a cable that runs to one or both wipers. Poke around a bit on the internet, and I think you'll see what I'm talking about. Better yet, if they have a British car club near where you live, reach out to the president / other officers, and I'll bet someone will be happy to show you their car so you can see how this setup looks in person. Pretty slick, actually ...
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