Windshield frame raw material

[Dangerous Doug]

Anyone familiar with the source for the windshield frame material?

In an earlier thread I mentioned fabricating a full-width racing windshield for my 289 FIA. I know this won't be "original" but I like the look of the Cobra w/o a full height windscreen, but don't want to use the USRRC-type screen which requires drilling into the body---I want to be able to swap between screens, standard and "racing".

Anyone else do something like this?

I'm pretty adept at fabrication, for a novice. This is a one-off, and since I'm not working at the moment I'm trying to do this in the least-expensive fashion possible.

DD

[Tjd]

The first car I did in 1981 I had to make my own windshield frame I could get the glass but I could not get the frame at that time or didn't have a connection to get it can't remember anyway I used a piece of brass bar stock then machine it on one side for the glass and groove on the other side for the top made the side post out of quarter inch brass then formed it in a fixture.
Then had a chrome plated.
And I was real happy when I could start buying the windshields frames.
Then I found an outfit that could make the extrusion for me but by then I was working for Shelby and they didn't want to pay that for 2000 pounds of extrusion
Which was a minimum order and it would've made A lot of windshield frames!
This is from my iPhone so please excuse if I have any mistakes
Tom

[Dangerous Doug]

Thanks for the reply. Not a lot of bites on this topic.

The uprights I figure I can make from 1-1/2' x 1/4" brass. The trick is the frame around the glass. I've found the rubber strip online for $30, so if I could find a source for the frame I could do the surround.

I've created a template for the Lexan. I've been drawing different shapes to get the look I'm after. A fun project.

DD

[strictlypersonl]

If you're not obsessed with a chrome finish, I would use aluminum material rather than brass. Lighter too.

[Dangerous Doug]

Hey, Bob! Good to hear from you.

I just today ordered the raw materials for constructing the frame. I selected aluminum, which is less expensive than brass and, as you point out, is lighter.

I'll post some pictures when I'm done.
DD

[KarlCSX2498]

Hello Doug, I have some spare parts. I know for sure I have the two uprights, brass with chrome, I have to look for the remainder of the frame. You can have the two uprights for free, let me know.
later, Karl

PM your address for UPS

[bobcowan]

Originally Posted by Dangerous Doug

Hey, Bob! Good to hear from you.

I just today ordered the raw materials for constructing the frame. I selected aluminum, which is less expensive than brass and, as you point out, is lighter.

I'll post some pictures when I'm done.
DD

I need to construct a windshield, too. Can you tell me what material you ordered, and what your plan is?

I'll probably use steel, because I can't weld aluminum.

[Dangerous Doug]

I have a hard time finding material locally, so I've been using onlinemetals.com.

They have brass flat bar in 1/4" x 1-1/2" for the uprights. I also found this in aluminum.

I only have rudimentary tools (no lathe or mill), so my plan is to use two 1/8" x 3/4" rounded edge flat bar (aluminum) and rivet the Lexan in place sandwiched between the strips for the bottom trim (with the rubber trim on the bottom).

It may sound funky, but when I looked at racing windshields I saw similar approaches.

My objective is to make a full-width 6" high windscreen that uses the standard upright mounts---as well as the center bracket---so I can interchange windshields without drilling extra holes in the body.

I got some heavy posterboard from the local art shop and made a full windshield template. I'll use this to cut and trim the Lexan (polycarbonate). Lexan in widths larger than 48" (you need ~53") are hard to find, but TAP Plastics offers wider sheets.

http://www.tapplastics.com/product/p..._sheets_ar/517

DD

[MOTORHEAD]

Hi Doug; I have been planing on doing the same. I have a complete spare frame, but the most important piece to me is the bottom rail that is formed to the contour of the cowl. Mine has been deformed by the heat of the engine fire my car suffered when new. In a Cobra book I have, there are pics of two identical Cobras except for the windshields , one has the cut-down w/s made from stock frame pieces that just looks sensational ! I think the book is "Cobra, the first 40 years" by Trevor Legate. Whats holding me back(besides the bottom frame piece) is I think the airflow (+ dirt, bugs,etc, would hit you square in the face), and require the use of goggles or helmet !!?? I'll be watching this thread with interest.
Best of luck.
Ted

[Dangerous Doug]

Motörhead: I suspect you're right on the airflow. I've driven my Cobra without the windscreen, and at 35 mph and in cool air my eyes water so much I could barely see. Sunglasses are no help, and actually made it worse. This may require goggles, which certainly reduces the "cool" factor for the driver.

I have the Cobra book to which you refer, so I'll dig it out and see if I can find the pics. That'll save me more conceptual drawing---and, possibly return me to the good graces of the Cobra purists.

DD

[Morris]

Doug ....like this.....7" to top of the frame.....

[Morris]

Dark 1/4" Lexan scratch resistant.....and it like riding a motorcycle.....

Goggles over glasses works for me.....once we used Red Baron hat with the goggles.....fun.....helmet on the race track......

[Dangerous Doug]

Morris: Wow! Exquisite work! I'd like to see a pic of your whole Cobra.

After that, I think I might be embarrassed to post photos of what I'll be able to cobble together in my garage shop...

Nicely done. Aluminum uprights? Tinted Polycarbonate AR?

DD

[Dangerous Doug]

Another thing I noticed is it's hard to hear the exhaust note for the wind noise...

DD

[Morris]

Doug....check out my Gallery.....I think you will be surprised.....

[Dangerous Doug]

Morris: Like to see some video of your Cobra in action!

[MOTORHEAD]

Doug: found pics on pages 212 & 213. also another option on pages 246 &247. Took pictures of the pictures to post, but that might violate copyrite.

[Dangerous Doug]

Here's a scanned image from Trevor's "Cobra: The First 40 Years". This is the design I had in mind, without a frame across the top.

This is AC MkIII COB5001, built in the mid-1990's as per Trevor's comments.

[Morris]

Originally Posted by Dangerous Doug

Another thing I noticed is it's hard to hear the exhaust note for the wind noise...

DD

Don't believe that..... if we don't wear ear plugs with a full face helmet ... then your head rings for a day or so....

[Dangerous Doug]

Another view of the racing windscreen from Trevor's book: