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Old 09-17-2007, 05:51 AM   #15
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Rock Guard Overhaul

I didn't realise that the spline was that hard to find. I have a Mom and Pop hardware store (Meadowbrook Hardware) close to me. I just go there first out of habit. They had it and the next size larger.
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Old 09-17-2007, 09:39 AM   #16
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Quote:
Originally Posted by Melody Ranch
Hey....if you have a star crack showing...its not Lexan. It won't do that.
Melody- my experience follows
Um ah, from one airplane builder to another. I've seen numerous instances of star cracking on lexan windscreens installed on experimental aircraft. This is almost always caused by the builder drilling out only to the called rivet size. The correct way is to drill out to the called rivet size then give it a little more clearance. I don't have the info here with my morning coffee, you'll just have to trust me on that. Why oversize holes?- because polycarb has movement when it heats and cools, if held tight it will crack. True Story. I posted pics some time ago on another thread, try the defunct search if you need something to do. Also with google availability anyone should be able to purchase lexan, polycarbonate anywhere on the planet and have it shipped to them. Plastic supply places have it all the time, it's readily available if you know where to shop.

on edit --look at the thread "rock guard rebuild-71 Safari" pics of star cracked lexan.
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Old 09-17-2007, 09:59 AM   #17
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absolutely correct..

Thats absolutely correct. After the first drill to size I will go one size over...plus I will use a large bit...or countersink, to bevel both ends on the drill hole. The star crack I was thinking of was from a direct blow...like a windshield type. Bullet holes don't count.
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Old 09-17-2007, 10:04 AM   #18
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I'll fly your stuff anytime!!
Nothin worse than a frozen chicken hittin the windscreen, thats the direct blow we do not need!
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Old 01-23-2008, 07:28 AM   #19
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rock gaurd

I'm interested in finding a source for the materials for building a rock gaurd....do you have that already? I'm in Va and get over to Norfolk once in a while.....

Quote:
Originally Posted by Beginner
I didn't realise that the spline was that hard to find. I have a Mom and Pop hardware store (Meadowbrook Hardware) close to me. I just go there first out of habit. They had it and the next size larger.
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Old 01-23-2008, 10:42 AM   #20
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Quote:
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Nothin worse than a frozen chicken hittin the windscreen, thats the direct blow we do not need!
I gotta ask... how often have you seen frozen chickens flying by when you are airborn?
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Old 01-23-2008, 11:01 AM   #21
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I gotta ask... how often have you seen frozen chickens flying by when you are airborn?
Happens to me often....on Saturday nights....Maybe the beer and BBQ has something to do with it.

I found a 4x8 sheet of Lexan at a local Mom-n-Pop glass shop for just under $200. I had to cut it myself to fit the old frame, which can be very tedious, but it came out really nice. Take a look: http://www.airforums.com/forums/496827-post466.html

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Old 01-23-2008, 11:05 AM   #22
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Quote:
Originally Posted by waltero
I'm interested in finding a source for the materials for building a rock gaurd....do you have that already?
Walt. I've seen a couple homebuilt rockguards on Forums in years past but wouldn't be able to put my finger on the location. I don't recall enough details to tell you how they were done. They didn't look that great nor offer the function that OEM rockguards do. An Airstream dealer should be able to tell you what is available. If your local dealers aren't interested, Out-of-Doors Mart gives great service.

1973 Caravanner? Guess I didn't notice that before. Vintage Airstream Photo Archives gives the last sample in 1970. The last Caravanner at http://www.airstream.com/docs/weights-1.pdf was 1971. Your Airstream should have an interesting story!
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Old 01-23-2008, 11:08 AM   #23
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And they have about the best price around right now. I looked at their site a couple of weeks ago and they were about $100 cheaper than others.
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Old 01-23-2008, 01:04 PM   #24
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Proper trade names for Acrylic and Polycarbonate

Just to clear up a couple of error in this thread. The original transparent rock guards were make from Acrylic sheet. Acrylic is the short generic name for PMPA polymer. Rohman Haas's trrade name fo it was Plexiglas. Dupont's trade name for the same material was Lucite. Cyro Industries and several others also made this polymer under various trade names. In error, many people just call it all Plexi.

Polycarbonate is the generic name for a higher impact polymer that was invented much later. GE named it Lexan. Bayer and Monsanto made the same kind of material under their own tradenames. GE recently sold their plastic business to Sabric so they now own the Lexan tradename. PC as the plastic people call it is a little softer than PMPA but much more impact resistant. PC and PMPA are sensitive to a variety of chemicals and can craze or crack when exposed to them when the material has a stress or an internal stress (like poorly drilled holes) applied.
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Old 01-23-2008, 05:15 PM   #25
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Quote:
Originally Posted by dwightdi
Just to clear up a couple of error in this thread. The original transparent rock guards were make from Acrylic sheet. Acrylic is the short generic name for PMPA polymer. Rohman Haas's trrade name fo it was Plexiglas. Dupont's trade name for the same material was Lucite. Cyro Industries and several others also made this polymer under various trade names. In error, many people just call it all Plexi.
This is the same issue that gets all cola-flavored sodas called "coke", all snowmobiles called "skidoos", and all aluminum trailers called "airstreams"...
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Old 01-23-2008, 06:53 PM   #26
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Air Force Test

Quote:
Originally Posted by overlander63
I gotta ask... how often have you seen frozen chickens flying by when you are airborn?
Terry,
I was referring to the testing the Air Force once did on canopys. They were trying to test for breakage should a midair occur with a duck or goose, problem is they were not thawing the chickens they were blasting at the canopies! I thought everyone had heard this story.
Or was that McDonald Douglas.
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Old 01-23-2008, 07:04 PM   #27
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"Gentlemen, thaw your chickens!"

Quote:
Originally Posted by doorgunner
Terry,
I was referring to the testing the Air Force once did on canopys. They were trying to test for breakage should a midair occur with a duck or goose, problem is they were not thawing the chickens they were blasting at the canopies! I thought everyone had heard this story.
Or was that McDonald Douglas.
I did hear the story, but the mental picture of frozen chickens flying around was perversely funny.
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Old 01-23-2008, 09:58 PM   #28
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Quote:
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I did hear the story, but the mental picture of frozen chickens flying around was perversely funny.
The first images that came to mind for me were those of the Mythbusters' "chicken cannon" where they fired frozen chickens at an old Piper's (I think) windshield. Made pretty short work of it, IIRC.

Now that's quality television!
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