On the inside of each windshield frame, there is a strip of .032 aluminum that "sandwiches" the lexan. I used the windshield frame pattern, moved it up 1/2 inch and cut out the bottom strip.
Then, the strip bends inside the frame and the corresponding holes are drilled. This is looking inside the frame. The curved flange attaches to the cockpit sheet metal.
Both the front and rear frames are ready for riveting. I have to go to MSC tomorrow after work and pick up some copper rivets for the copper section of the frame.
ANATOMY OF A BRACKET
This shows the steps required to make one simple bracket - cut strip from sheet steel (3/4 in) - measure 3/4 inch ends - bend- cut - round edges - drill.
It does not seem like much, but five brackets are needed. They hold the sheetmetal to the instrument panel like shown below.
More soon. Enjoy