by Chappy » Thu Mar 10, 2005 11:34 pm
Darn, Karl beat me to it. I also would highly recommend small wellnuts and stainless steel Phillips pan head screws. Drill the holes slightly oversize. When I replaced the windshield on my Avenger, I did it this way rather than use pop rivets again, and it worked out very well. I used very small wellnuts, IIRC #6 screw size. I purchased a box of 100 from a commercial hardware supplier and they weren't too pricey. On some machines, like my Avenger when I owned it, it was very convenient to be able to easily remove the windscreen.
Something else that might be of value. The first Lexan windshield that I made didn't hold up too well. It had a fair curve imposed on it when mounted, and over a period of a year or two developed a lot of very small stress cracks and stars on the outer surface. Eventually, I made another new one, but after I mounted it, I used a heatgun on it passing it over the outside to stress relieve it some. I used enough heat to get it somewhat warm, but not near warm enough to melt it. That windshield never developed the little cracks and stars that my first replacement did.
Chappy