Gunner, thanx for the tips-I did not oversize the holes,but if you have ever seen a 71 frame-is very flexible-am hoping that it will expand or contract with the lexan! I will watch them closely-As you can see my lexan is only slightly tinted [its all they had]-I wonder if something could be added to the underside to make it alittle darker?--thanx--jim
just keep watching it! Seein as you never leave the dirt no one will get hurt!!I kinda like the lighter shade, makes for a brighter winter day. Hey maybe you should have a winter and a summer sheild. Have fun Tim
Just bought a '72 Safari yesterday and sadly it doesn't have the rock guard. This lexan solution looks great, all I need is a frame. Does anyone out there have one they would be willing to give up?? If so, please PM with info.
Yeah, this bender can but I thought for once I would make it just a little easier on myself since I have higher priority items to take care of on my new project. Interior panels to pull and magic to work on a misaligned entry door before it rains again.
tinbender-I would bet there are plenty of em around-most are afraid to use em cause they are so flexible-[the original plastic was moulded and added strenght to the frame]-But it appears that all is well if you use 1/4" lexan-at least mine is traveling well--try a new post requesting one-I'll bet someone has one for you--good luck----jim
Tinbender- just having fun- another thought, Most of the window frames on the small experimental airplanes are formed with 3/8" .032 6061T6 Alu. Some anodized some not.Good for 130 mph.Will send a few images if you request em. Nothin beats a pair of cheap sunglasses! Tim
While this is an older thread, I am reviving it to post some pics of my rock guard rebuild--with much thanks to Jim for showing that it could be done! Judging from his photos, my workmanship is not to Jim's standards but I was in a hurry get on the road last summer (and also had to build a new battery box).
I used 1/8 inch polycarbonate--shop carefully as I found a sign shop to be double the price of a plastics dealer! As noted in a previous post, the frame is very wobbly without the plastic, and they rely on each other for strength. I didn't have a rivet puller when I started, so I went to the 'big orange box' for stainless screws and nuts. Yikes, retail stainless is such a ripoff, so lesson learned. I then bought the rivet puller as I was finishing this project.
I trial fitted the polycarbonate into the frame and drilled and countersunk the holes (for the screws). Then I removed the plastic from the frame to clean out the shavings. That ended up being a lot of work, as everything had to be lined-up and clamped again. In the end, it worked out well. I flipped the brace bracket around as Jim suggested, and had to make stand-offs for the bottom of the frame. I used my new rivet puller to attach those! While trying to bend the stand-offs in the vise, they kept cracking at the bend, and I ran short of aluminum flat bar, so I had to cobble together one of the stand-offs (note the double rivets in one of the photos). I wasn't able to put as much curve in the dividers to allow for brace clearance as Jim did, so my stand-offs had to be a bit deeper to keep the braces away from the window frames when closed.
I hope someone else can benefit from the photos--good luck. And thanks Jim!!
I used 1/16" Lexan which is closer to the original thickness that 1/8" a 4x8 sheet cost me about $50. I did not reinstall the braces, but may use some of the above ideas to get the clearance. However, with the 1/16 Lexan the rock guard is light enough to rest on the open front window.
Where can you get a rivet puller?
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Pay no attention to the man behind the curtain- WoZ
great lookin guard 4slice!- are those underbelly rivets that you usedon your brace arms? I really appreciate the protection when traveling down the road-----jim
Quick Links
Re-built Rock Guard 
While trying to bend the stand-offs in the vise, they kept cracking at the bend, and I ran short of aluminum flat bar, so I had to cobble together one of the stand-offs (note the double rivets in one of the photos). I wasn't able to put as much curve in the dividers to allow for brace clearance as Jim did, so my stand-offs had to be a bit deeper to keep the braces away from the window frames when closed.
Hybrid Mode
