Next, we trimmed the sides for the butt ribs and the firewall line. It will still definitely need quite a bit more trimming in the front but making small cuts prevents having to get a whole new sheet.
Once the the top sides were trimmed to fit, we trimmed the cutouts for the spar and the wing root fairings.
At this point, we decided to pause and use a slip sheet to get our cut lines a little closer. We had an idea of where we wanted to cut the Lexan but decided to be safe with the cardboard and use that. We clamped it at the front of the butt ribs and ran it down just like the real windshield.
We also took the time to fit in the top of our instrument panel at this time. We used a slipsheet with a pattern that Jack had designed first and then traced onto this aluminum sheet from an old cowling. We wanted to get this done now so that we could make sure it fit properly as we set up the windshield.
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