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I've just replaced one windshield and one door on my Xair Falcon.

I used Lexan which is a top brand of Polycarbonate Sheet.

I was advised to use 1.5mm as its easier to cut. Having bought it I found the original on my aircraft was 2mm.?? My windscreen is in 2 halves and I have only replaced one half. In the air I notice the 1.5mm deforms more than the 2mm and it wobbles a bit on full power.

Its not a big issue but if I was ordering again I think I would stay with 2mm for the windscreen. On the doors it makes no difference and 1.5mm is fine.

I cut it using tin snips with a dremel on the dv port on the door window.? I had no problems cutting it.

Don't use a jigsaw as it will split. When drilling screw holes make them large enough to allow for any expansion or movement. If they are tight the Lexan may crack around screws.

regards,

Jonathan

Jonathan Webb 

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I've just replaced one windshield and one door on my Xair Falcon.

I used Lexan which is a top brand of Polycarbonate Sheet.

I was advised to use 1.5mm as its easier to cut. Having bought it I found the original on my aircraft was 2mm.?? My windscreen is in 2 halves and I have only replaced one half. In the air I notice the 1.5mm deforms more than the 2mm and it wobbles a bit on full power.

Its not a big issue but if I was ordering again I think I would stay with 2mm for the windscreen. On the doors it makes no difference and 1.5mm is fine.

I cut it using tin snips with a dremel on the dv port on the door window.? I had no problems cutting it.

Don't use a jigsaw as it will split. When drilling screw holes make them large enough to allow for any expansion or movement. If they are tight the Lexan may crack around screws.

regards,

Jonathan

Jonathan Webb 

On 23/09/2024 07:05, Tom Yoder via groups.io wrote:

I'm looking at replacing the windshield on my H. I think a few here may have done so previously and was hoping someone could advise on what material (polycarbonate or acrylic) and thickness has been used.

I'd really appreciate any guidance anyone could give.

?

Thanks,

Tom

?

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mailto:mcoates@...


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How large of a sheet did you need?

On Sep 23, 2024, at 17:35, Brent xair via groups.io <Dunphystowing@...> wrote:

?

I used 1/8 lexan . Worked good. Very strong

On Mon, Sep 23, 2024, 2:05?a.m. Tom Yoder via <kymidnight=[email protected]> wrote:

I'm looking at replacing the windshield on my H. I think a few here may have done so previously and was hoping someone could advise on what material (polycarbonate or acrylic) and thickness has been used.

I'd really appreciate any guidance anyone could give.

?

Thanks,

Tom

?

-- 
With regards,    Michael Coates

AU +61 7 5522 0583


mailto:mcoates@...


Please note: because of the volume of e-mail we are now receiving our replies are
done using voice recognition software in an effort to speed up the reply process. 
Sometimes the voice recognition program inserts silly words or doesn't actually
do what it is meant to do.  Occasionally these mistakes get through our quick
proofreading of each e-mail sent, so please accept my apologies if the odd mistake
gets through.

Legal Notice: The information contained in this email is confidential
and intended only to be read by the person(s) to whom it is addressed.
No one is authorized to copy, use, disclose, distribute or rely on this
information for any purpose whatsoever. If this communication has been
sent to you in error, please email the sender and delete the message.

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Yeah, I wasn’t able to check yet, I was just hoping a 60”x30” sheet would be big enough. My local Lowe’s has those in stock.

On Sep 24, 2024, at 17:41, Michael Coates via groups.io <mcoates@...> wrote:

? The standard size sheet of Lexan/polycarbonate is 8' x 4'

Tom Yoder wrote on 25/09/2024 5:07 am:

How large of a sheet did you need?

On Sep 23, 2024, at 17:35, Brent xair via groups.io <Dunphystowing@...> wrote:

?

I used 1/8 lexan . Worked good. Very strong

On Mon, Sep 23, 2024, 2:05?a.m. Tom Yoder via <kymidnight=[email protected]> wrote:

I'm looking at replacing the windshield on my H. I think a few here may have done so previously and was hoping someone could advise on what material (polycarbonate or acrylic) and thickness has been used.

I'd really appreciate any guidance anyone could give.

?

Thanks,

Tom

?

-- 
With regards,    Michael Coates

AU +61 7 5522 0583


mailto:mcoates@...


Please note: because of the volume of e-mail we are now receiving our replies are
done using voice recognition software in an effort to speed up the reply process. 
Sometimes the voice recognition program inserts silly words or doesn't actually
do what it is meant to do.  Occasionally these mistakes get through our quick
proofreading of each e-mail sent, so please accept my apologies if the odd mistake
gets through.

Legal Notice: The information contained in this email is confidential
and intended only to be read by the person(s) to whom it is addressed.
No one is authorized to copy, use, disclose, distribute or rely on this
information for any purpose whatsoever. If this communication has been
sent to you in error, please email the sender and delete the message.

-- 
With regards,    Michael Coates

AU +61 7 5522 0583


mailto:mcoates@...


Please note: because of the volume of e-mail we are now receiving our replies are
done using voice recognition software in an effort to speed up the reply process. 
Sometimes the voice recognition program inserts silly words or doesn't actually
do what it is meant to do.  Occasionally these mistakes get through our quick
proofreading of each e-mail sent, so please accept my apologies if the odd mistake
gets through.

Legal Notice: The information contained in this email is confidential
and intended only to be read by the person(s) to whom it is addressed.
No one is authorized to copy, use, disclose, distribute or rely on this
information for any purpose whatsoever. If this communication has been
sent to you in error, please email the sender and delete the message.

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