Hello All,
Unfortunately, I may need to replace the Lexan Windscreen on my B model Sonex project (in addition to already replacing the plexi Canopy months ago). I had posted last year about getting thread cutting oil (just ignorance) on the canopy (and Windscreen) when drilling the holes in bows and it resulted in extreme cracking of the Canopy (and I had to replace it). Sadly, the Lexan Windscreen is doing the same thing now (albeit not as bad), it just too longer. I’m trying to stopdrill and salvage things, but replacement may be necessary in order to ever fly.
I’ve searched the forum (beg forgiveness if it’s there) and didn’t see any posts that describe steps, i.e. HOW others may have gone about getting the bad windscreen out and getting the new one (again, after all the installation riveting and fasteners have been completely put in). Any suggestions (or where it is on the forum) on this would sure be appreciated.
Thanks!
Neil Payne
Not sure how different the B model is, but for the A model it’s just unbolt and remove. I’d probably lay the old one out flat, transfer the shape and maybe holes to the new windscreen.
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Agree with Bryan with the following advice;
Be sure the old windscreen is fitting (holes & dimensions) as you would want. No point in using a bad pattern (old screen) to make a new screen. 
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Just be sure any and all tools used to cut or drill the Lexan are free of all oils and other contaminants, and that all edges are sanded smooth and holes deburred.
David A.
Yea I believe just undoing the 100 nuts holding it and sliding it out should do it. Getting the new one in won’t be easy but doable!
I used alot of cutting oil on the titanium gear legs. Everything that stuff touched has some of weird fuzzy corrosion on it now. My drill press has this icky rustyish fuzz all of it and the surrounding area. It ate the paint off a workbench I am using as well. Apparently tapmagic cutting oil has chlorine in it which attracts rust…yay.
Perhaps opening the holes up another 1/32” will aid in getting things lined up again?
Thank you all for weighing in! I realized after posting initially that the Legacy Windscreen was not under a skirt like the B Model so to many, it would seem a somewhat silly question. As you said “SNB0047”, it won’t be easy but where there’s a will… (BTW my kit is #SNB0048)
As stated initially, I may be able to delay replacing the windscreen for a while (by stopdrilling and maybe cementing with Acrifix), But eventually the cracks will probably win. That threading/drilling oil is mean stuff in the wrong place; WARNING! Do not get it near the Lexan or Plexi Canopy. Will report back if/when I know more.
Neil P