Windscreen Part 1

Time to fit the windscreen - what a marathon this became.  It seems I am so close to finishing yet every "little job" ends up taking forever to complete, no exception here.

The windscreen surround is roughly the right shape but isn't close enough to tighten into place:

I had driven down to the factory to pick up the glass and with such a delicate item I decided to make a template out of some scrap board in the garage.  After some bending I managed to get the correct shape:

The corners need to be fastened together with a No4 screw cut to length, there really isn't a big enough target to hit without risking screwing into the glass without adding some material.  I took an offcut of the frame and drilled it out:

Once both sides were ready I cut the bottom frame to length, here is the result - pretty good:

It turns out cutting to length wasn't the best idea, I hadn't taken into account the rubber strip required when fitting the glass meaning the ends were too short.  You will see later on how I fixed this.

The actual mounting brackets needed to be bent to shape - lots of heating in the oven and some creative vice work later I had a decent fit:

Note the center lines used to make sure everything is central and lined up.  Not many pictures for hours of effort and fiddling to get to this stage.