Remove Compass ( if mounted on center post ) and
Outside Air Temp gauge (OAT).
Remove old windshield by removing center outer
strip and lower farings. The windshield is removed by pulling it
down from the upper channel.
Remove side retainer strips by drilling out the
rivets ( approx. 12 ea. side ). This step may be done before removing
old windshield if desired.
Cover the top of the instrument panel to prevent foreign
material from entering radios and instruments ( masking tape may be
used to seal the top if desired ).
If compass is to be located other than on center top of
windshield remove center post and brackets by drilling out the
rivets (see fig 1 below). If compass is to be located center
top of windshield drill out the bottom rivets and cut center post as
fig 2 below).
Clean the old sealant from the windshield mounting area and
carefully inspect and repair the mounting surface to remove nicks,
burrs and distorted metal as required.
Remove the edge of the protective paper as shown on Fig 3.
Fit the new one piece windshield to the opening by trimming -
use a disk sander or a belt sander - be careful not to remove too
much material ( you can not put any back on, but you can always
remove a little more ). When the windshield fits properly,
chamfer the edges so the contour fits the fairings nicely.
Mark and notch the 6 holes at the top ( See Fig 4)
Smooth all edges with fine sandpaper to remove all notches.
Apply sealant to all mounting surfaces and reinstall windshield
Reinstall lower outer fairing and side post retainers using the
related hardware ( See fig 5 )
Clean the excess sealant and windshield ( VM&P Naphtha or lighter
fluid will not harm the Plexiglas but most other solvents will ).
Use a good grade of aircraft windshield cleaner to remove the thin film
that will remain after cleaning the sealant with the VM&P Naphtha.
Reinstall the O.A.T. - it may be installed thru the windshield but
it is desirable to relocate it elsewhere.
Reinstall compass as shown in Fig 6 or relocate as desired - A
C2400L4P may be mounted on top of the instrument panel.