Of all the challenges that constructing this airplane presented, I would have never suspected that installing the windshield would have been this difficult. The material is K&S Engineering 0.010" clear polyethylene terephthalate copolymer (PETG), or in English, plastic. The adhesive of choice is J&Z Products Super RC Z56. This stuff goes on white with a similar consistency to Elmer's glue, but dries clear.
So on the first attempt I try to glue around the entire perimeter and use blue painter's tape to secure it until it cures. The next day I pull off the painter's tape and the windshield releases around the upper corners. There was not saving it, so I pulled it off and cut a new one. Fortunately the cured glue cleans up easily with denatured alcohol. For round two, I decided to start by just gluing the top edge and let that set up overnight. The following evening I glued the rest of the perimeter and taped it up. The next day I find that the sides are glued but now the top has separated. So I added some more glue where it separated and taped it down. The following day the top is glued but the sides are starting to separate. Round and round we go...nowhere fast. I add a little more glue to the sides but that just doesn't get it. It's still separating.
It's becoming rather obvious that this operation will require some advanced engineering techniques. So on Friday night, after work, I start drinking some beers. By beer #7 I begin
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