Protective plexi front panel

[slk]

Hey guys I have a a 1996 Excella that just got the right front protective cover busted out. Does anyone here know if you can get used ones or how much a new replacement should cost.

Thanks Steve

[dznf0g]

Originally Posted by slk

Hey guys I have a a 1996 Excella that just got the right front protective cover busted out. Does anyone here know if you can get used ones or how much a new replacement should cost.



Thanks Steve

If the frame is still good, why not fab a new panel. I replaced all 3 of mine with polycarbonate.

[slk]

Can you get that stuff in that dark tint? Also how hard is that stuff to form to the curvature of that window?

Steve

[dznf0g]

Originally Posted by slk

Can you get that stuff in that dark tint? Also how hard is that stuff to form to the curvature of that window?



Steve

I have been searching for my thread on my replacement. I bought sheet polycarbonate from a plastics manufacturer locally. Quite easy to work with and made the bend on my 2007 very easily.

[dznf0g]

https://www.airforums.com/forums/sho...d.php?t=196079


Replacing your plexi glass Rock Guards / Stone Guards

Wasn't my thread, I tagged on. This should be helpful.

[richard5933]

Looks like Minneapolis has at least 3 plastic supply houses. They will likely have the color and thickness you need in stock, and if not should be able to get it easily.

They will cut to rough size as well to make it easier to get it home if you need, but you should plan on doing the final cutting to the exact size. There is a possibility that they'll be set up for accurate cutting, and if so they might be able to make you new panels using your original ones as templates.

If the color is slightly off, just replace all three.

[slk]

I know this may be a long shot but does anyone here have a pattern for one of the corner pieces for an excella?

This is the damage

[dznf0g]

Originally Posted by slk

I know this may be a long shot but does anyone here have a pattern for one of the corner pieces for an excella?

This is the damage

No 2 are the same, I'm afraid. I would make a paper pattern of the outside of the frame, then do your best to draw inside that shape...perhaps 1/8", or a bit more. Then sand to fit.

[slk]

I just had an idea.. Why couldn't you after cutting the plexiglas lay it over the outside of the aluminum frame and run a heat gun over it slightly and see if it starts to bend a little into the curvature of the frame???? Or leave it in the sun for an hour or so before trying to get it into the frame?? Or am I just over thinking things here. I know people have stated it can be cold bent. I suppose that 1/8" should be pretty flexible.

Steve

[dznf0g]

Originally Posted by slk

I just had an idea.. Why couldn't you after cutting the plexiglas lay it over the outside of the aluminum frame and run a heat gun over it slightly and see if it starts to bend a little into the curvature of the frame???? Or leave it in the sun for an hour or so before trying to get it into the frame?? Or am I just over thinking things here. I know people have stated it can be cold bent. I suppose that 1/8" should be pretty flexible.



Steve

PM sent. Sun won't do it for curving. Heat gun will, but it is difficult to get enough heat over the large area consistently for an even smooth curve. It is also really easy to "burn" a spot with too much heat in is single spot.

[slk]

Ok I have to be over thinking this. The straight part of the protector is perpendicular to the center window guard. It has 45* cuts where the pop rivets are. The curved piece runs parallel to the trim piece on the trailer, so you would naturally think that coming off of the straight piece things would run square,,,,Wrong. I am brain dead thinking this out. Now to boot from top to bottom on both sides and in the middle (the height) the measurement is 26 1/2"

[richard5933]

Remember, you're working with a window protector which is roughly following the shape of the trailer, and that shape has few things which sit in right angles or which are truly perpendicular to one another. They may look like it from 10 feet away, but due to the complex curves and angles of the body sides things are not what they appear.

I think that the best way to make the template will be to use some type of thick cardboard which is not corrugated. Have a helper or two hold the cardboard against the outside of the frame and trace against the frame with a pencil. Then move that line inwards about 1/4" as a starter to allow for the frame thickness as well as to provide a small gap between the plexiglass and the frame.

Cut this out and give it a trial fit. If needed trim the cardboard till it fits.

[slk]

Well yes that was my plan to use poster board. I was just trying to reason with the geometry of things. I plan on making a template and transferring it to a full size plywood template and then using a router. Was going to save the template for a just in case issue again....
Steve

[CaliDreaming]

If you can use a drill and a rivet gun, as an airstream owner you should, then it is easy to drill one side of each of the three frames, remove the aluminum frame side, slide out the plexiglass. After that you trace around the 3 plexiglass panels on butcher paper with a Sharpe. Then mail the three traced panels to: The Plastics Guy: https://theplasticsguy.com/ or call (916) 728 8264. Each airstream is a different shape, and you must trace your own plexi. He mails them back to you and you just put them back in with a perfect fit and no cutting. 4 hands are easier than 2. You don't even have to remove the frames from the trailer. The look is brand new front: spectacular!

[Okiegent]

I just did all three on my 83 excella. No need to bend material is 1/8” thick will slide in easy. Drill a few rivet’s out of frame slides old protector out side New in. Maybe a little more preparation but real doable.

[slk]

Ok guys I am now understanding the geometry of the curved windows..Made the pattern today and made a template and I will use a router to cut them to the template. Oh and BTW both sides of mine are identical. I will get it installed tomorrow and take pics of finished product.

[Okiegent]

Not sure what everyone odds talking about template. These windows will conform on their own to the curve. The glass is 1/8 thick. If you cut your material to the same outside dimensions give a little if you need to sand some. Then they will naturally bow when slid in. At least mine did.

[slk]

Piece of cake job... Here is the finished side window. Same shade of darkness just shinny and new looking

Thank You for everyone's help

[epen274425]

Check out "sailrite" on the net. They have a ton of great videos on making boat covers etc. There is a vid of how to make the compound curve you'll need. I am currently making making a sunbrella window cover for my 1993 Excella front window.

[jdm-mn]

The rivets don't seem to be conventional pop rivets. Are they? It seems to me that 1/8x1/8 are a little too long to work with the pop head taking up space. I see closed end/mandrel rivets on Amazon. Which works or where do I get the right type?