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Old 12-04-2017, 01:16 PM
goatflieg's Avatar
goatflieg goatflieg is offline
Join Date: Jul 2013
Location: Clarkston, MI
Posts: 314
Default Tip: Bending Windscreen Support Weldment

Most builders have had fit issues with weldments at some point. I had a fairly major one with my WD-814 windscreen support/roll bar. When I test fit it initially, it had the usual problems; the forward part of the triangular gussets were raised up a bit, and it didn't fit very well between the vertical tabs and the fuselage cockpit rails. If I snugged up one side, it left me with a 5/16" gap between the tab and the rail on the other side. That's quite a gap:

I checked for possible solutions here, but didn't find much info on the side-to-side issue, so I called Van's builder support. They said it was a common problem and that I should definitely spread the hoop slightly so that the tabs will fit the fuselage. We discussed various ways to do this. I had tried the "armstrong" method of holding one end down on a padded surface with my foot and pulling upward... but I knew right away my back wouldn't care much for that. So I did some thinking... and came up with this solution. I used my cherry picker; securing a chain around the base, wrapping tie-down straps around either side of the hoop and securing them to the base chain and lifting hook, and carefully extending the boom to stretch the hoop:

I would stretch it a bit, let it spring back, and check measurements:

Eventually, after a couple bending sessions and a couple test-fits, I got it to fit just right:

I was so happy with the result, I wanted to share it right away. Van's said that the triangulated braces would probably pull together with the canopy rails with the bolts tightened; if I do any tweaking to those, I'll also share it here.
Martin J Filiatrault
Clarkston, MI
RV-8 #83507 - empennage complete (except fiberglass)
QB wings & fuselage work continues
N657AR reserved
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Dues paid for 2017... extra payment included for psychological therapeutic services rendered.


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Old 12-04-2017, 07:48 PM
greghughespdx greghughespdx is offline
Join Date: Nov 2011
Location: Hillsboro, OR
Posts: 401

Yep, I did something similar and found that the bolts snugged everything up to the rails quite well once tightened down properly.
Building RV-8A as of September 2014 (N88VX reserved)
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Flying a Warrior PA28-151 and a few RVs here and there
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Hillsboro, Oregon (EAA 105)
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Old 12-04-2017, 08:05 PM
Stoo Stoo is offline
Join Date: May 2006
Location: LL10, Naperville, IL.
Posts: 47

Good tip, Martin! The roll bar on my 6 slider needed to be tweaked the other way. Used my floor mount drill press as a big arbor press to make it fit!
Stewart Willoughby, 6 panel/wiring
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Old 12-04-2017, 08:06 PM
Neal Trombley Neal Trombley is offline
Join Date: Aug 2016
Location: North Fort Myers
Posts: 210

pure genius
Neal Trombley
SW Florida
EAA 66
N517NC ( reserved)
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NOV 2016
July 2017
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