Fabricate New Windscreen Frame, Fit Glass and Seals

Task Description

Fabricate and weld a new windscreen frame due to rust or damage in the original. Install new glass with proper seals and weld on new hinges and fittings for the folding windscreen mechanism.

Parts Required

• Steel tubing for frame (appropriate diameter)
• Sheet metal for corner gussets
• New windscreen glass (laminated safety glass)
• Windscreen rubber seal
• Hinges (heavy duty)
• Windscreen catches/clamps
• Welding consumables
• Primer and paint
• Sealant/adhesive for glass
• Stainless steel hardware

Tools Needed

• Tube bender or access to one
• Welder (MIG/TIG)
• Angle grinder
• Tube notcher
• Measuring tools
• Level
• Glass suction cups
• Rope or cord for seal installation
• Drill and bits
• File set
• Safety equipment

Procedure

Frame Fabrication

1. Remove old windscreen assembly completely
2. Document all mounting points and dimensions
3. Create template from old frame or vehicle opening
4. Cut tube sections to length
5. Notch tubes for corner joints
6. Create corner gussets from sheet metal
7. Tack weld frame together
8. Check fit in vehicle opening
9. Complete all welds
10. Grind welds smooth
11. Test fit repeatedly during build

Hinges and Hardware

1. Position new hinges (check alignment carefully)
2. Reinforce hinge mounting areas if needed
3. Weld hinges to frame and vehicle
4. Install windscreen clamps/catches
5. Test folding mechanism operation
6. Adjust for smooth operation
7. Lubricate all moving parts

Glass Installation

1. Clean frame thoroughly
2. Apply primer and paint to frame
3. Install rubber seal in frame groove
4. Use rope technique to install seal over glass
5. Carefully position glass in frame
6. Work seal completely around glass
7. Ensure seal is properly seated
8. Apply sealant if needed
9. Install any trim pieces
10. Clean glass thoroughly

Final Steps

1. Check windscreen opens/closes properly
2. Verify weather seal when closed
3. Test for water leaks with hose
4. Adjust catches for proper tension
5. Add bumper stops if needed

Notes

The folding windscreen is a signature Haflinger feature. Ensure the mechanism works smoothly and locks securely in both positions. Consider upgrading to stainless steel hardware to prevent future rust. Glass installation is delicate - consider professional help for this step if unsure.

Progress Updates

Task updates will be added here as work progresses