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Old 12-03-2013, 06:29 PM   #1
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1991 34' Excella
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Polisher 1, Window 0

I just finished making a replacement HEHR window and thought I'd hit the bench polisher real quick.

That didn't take long to ball up the entire frame when the polisher grabbed it. At least it wasn't a vintage unit, I can build another.

Be careful if you are gonna try to bench polish one of these things.
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Old 12-03-2013, 06:49 PM   #2
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Be careful is right, and always have the wheel going off the surface over the edge, never toward the edge. It can catch and ruin your part in an eye blink and might even throw it across the shop.
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Old 12-03-2013, 07:20 PM   #3
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Ouch I feel for you. That's totally something I would do....
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Old 12-03-2013, 07:51 PM   #4
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I tried the bench polisher once......that was it....it flung whatever I was polishing (can't remember--I block trauma out of my mind!) Sorry about your window--what a bummer! At least it didn't decapitate you!
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Old 12-03-2013, 08:06 PM   #5
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1st - wheres the thread on this replica window? I wanna see!
2nd - this does not belong to a 91 or a 63...
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Old 12-04-2013, 07:36 PM   #6
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Quote:
Originally Posted by NJtoNC View Post
1st - wheres the thread on this replica window? I wanna see!
2nd - this does not belong to a 91 or a 63...
Well, you are correct, it isn't for a 91 or a 63. I'm helping out a friend with a '55 and one window was missing.

Here is how a window starts life. Figuring out the blank is 1/2 the challenge, the bend sequence is super critical.
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A honkin' long 34' named AlumaTherapy http://www.airforums.com/forums/f205...num-54749.html
and a 26' '63 Overlander, Dolly http://www.airforums.com/forums/f109...ome-71609.html
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Old 12-04-2013, 07:43 PM   #7
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I need friends like you! Nice work... The window, not the polishing job

I've had that moment when I was polishing on of my overhead lights
Thankfully nothing Aerowood's roller couldn't get out
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Old 12-04-2013, 08:02 PM   #8
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id love to see more pics of the stages of the window. How will you replace the opening hardware? Will the window be fixed?
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Old 12-05-2013, 11:30 AM   #9
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1991 34' Excella
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Here are a few shots of the forming, as you can see I went ahead and made 2 frames...

I really only need the portion that opens on this project. I now will make the brackets that hold in the glass and cut out the opening for the glass. This will be for a crank open window and I'm still figgerin' up the center bar. The OEM versions use an extrusion that is NLA, I may mill one from bar stock. I have not been able to recreate the rolled hinge so a hidden piano hinge may have to be used.

For kicks and giggles I might go ahead and build the stationary frame for the spare window part that I just bent up.
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Hi Ho Silver RV! Vernon, Sarah, Mac the Border Collie -
A honkin' long 34' named AlumaTherapy http://www.airforums.com/forums/f205...num-54749.html
and a 26' '63 Overlander, Dolly http://www.airforums.com/forums/f109...ome-71609.html
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Old 12-05-2013, 05:12 PM   #10
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Neat-o. will you please post more as you proceed?
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Old 12-05-2013, 05:17 PM   #11
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Wow! I wish I had that capability.
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Old 12-05-2013, 05:44 PM   #12
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1991 34' Excella
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I cut out the opening with a nibbler and guide. It's an ugly way to do it but the best I have. A big file followed by scotch brite pads hides all of the ugly.

A few more steps and we will be ready to install it.
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Hi Ho Silver RV! Vernon, Sarah, Mac the Border Collie -
A honkin' long 34' named AlumaTherapy http://www.airforums.com/forums/f205...num-54749.html
and a 26' '63 Overlander, Dolly http://www.airforums.com/forums/f109...ome-71609.html
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Old 12-05-2013, 05:56 PM   #13
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Very impressive!!
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Old 12-06-2013, 08:35 AM   #14
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Nice work, I made a couple of those mid sixties hatches. It was fun. I also tried to make the rolled hinge also but was unable to do so. I believe they are roll formed. Nice brake
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