Adding captive nuts to the windshield.

My Stalker windshield is held to the scuttle by 10 bolts. To remove the windshield I have to remove the scuttle to access the accompanying nuts.  Removing and lifting the scuttle is non-trivial. I would like to be able to easily remove the windshield so that I can start trying to fit my new windscreen design.

Ten bolts with nyloc nuts hold the windshield to the scuttle.  You have to pull the entire scuttle to remove the windshield.

Ten bolts with nyloc nuts hold the windshield to the scuttle. You have to pull the entire scuttle to remove the windshield.

The scuttle is fiberglass which makes riveted nut plates impractical.  Tee nuts (also called blind nuts) can’t be used either, without additional material.   I replaced the nyloc nuts with tee nuts, but had the prongs pointed away from the fiberglass.  Then I mixed up some fiberglass jelly and sculpted a mound of jelly to keep the nut from twisting.  This jelly is polyester resin with chopped fiberglass embedded.  It is much harder than stand body filler and is strong enough to keep the tee nuts from twisting when the bolts are tightened.

Fiberglass jelly built up over tee nuts will allow the bolts to be removed and replaced without pulling the scuttle.

Fiberglass jelly built up over tee nuts will allow the bolts to be removed and replaced without pulling the scuttle.

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