Windscreen frame
 

So, yesterday night I've bent the windscreen frame. It was easier than expected.

I've bought a couple of 2m lengths of 12x12x2 mm channel. For the template I used two sheets of 4 mm plywood. I had to sand them down a bit for them to fit into the channel, snugly. The yellow roller is printed for the job.

The key was to anneal the channel. I've rubbed the bend with soap and heated the channel on the gas stove until the soap blackened, then let it cool in air. After this, the bending was surprisingly easy and smooth, and the result was perfect both times from the first try. Adding or removing a couple of degrees to match the cardboard template by hand was easy. The channel should harden in a week.

Nice work what are you going to use for a seal ?

Also do you mean you used a 3d printer to make the wheel?

Yes, I used a Prusa i2 3d printer to make the roller. I'll try a bike inner tube as the seal, if that does not work, then maybe PU glue like Sikaflex.

Have you thought how you will attach the ali screen frame to the side supports if there is no room between the frame and glass for either a nut or bolt head to sit?

Good question. Tap into the 2 mm extrusion? Make a 3 mm threaded steel insert?

Weld it on !;)