Windows and Lenses

Question 1

What are the 2 main categories of plastics?

Answer 1

Thermoplastics

Thermosetting plastics

Question 2

1st category of plastic:

plastics that can be softened by heat and dissolved in various organic solvents.

example: toluene, turpentine, acetone, methyl

Answer 2

Thermoplastics

Question 3

Why we use plastics usually?

Answer 3

It’s more lighter than glass windshields

Question 4

Cellulose Acetate Plastic
Acrylic plastic
Polycarbonate plastic

Answer 4

3 categories of thermoplastic

Question 5

Type of thermoplastic?
-can be softened by heat and dissolved in various organic solvents

• not commonly used anymore
• Subject to dimensional instability. Extracts too much with heat
• turns yellow with time

Answer 5

Cellulose Acetate Plastic

Question 6

Type of thermoplastic?
-quite common in the industry, moderately strong, easy to handle

• can be quite brittle when under load, easily scratched
• Trade names are Plexiglass, Lucite, Perspex

Answer 6

Acrylic Plastic

Question 7

Type of Thermoplastic?
-Contains Bisphenol. Use safety gear and VERY COMMON to aviation industry

• Trade names: Lexan, Makrolon, Makroclear
• Extremely effective at transmitting light, very high impact resistance, but easily scratched
• It can undergo large plastic deformations without breaking

Answer 7

Polycarbonate plastic

Question 8

2nd Category of plastic

• do not soften under heat. Molded to it’s final shape
• Blisters at temperature of 400⁰F to 500⁰F

Answer 8

Thermosetting Plastics

Question 9

a POLYCARBONATE transparent plastic that has excellent cold working properties and can be bent to a fairly tight radius without having a failure.

Answer 9

Lexan

Question 10

an ACRYLIC transparent plastic may also be cold bent if material thickness is thin and bending radius is at least 180x the thickness of the material

Answer 10

Plexiglass

Question 11

If acrylic plastic is bent beyond limits, local stress at the surface will cause tiny fissures or cracks to form. This type of damage is called _____?

Answer 11

CRAZING

Question 12

How to store plastic sheets?

Answer 12

Lay it 10 degrees angle or stack it horizontally

Store away from heat !very important!

Question 13

What do you need cleaning in cleaning the window?

Answer 13

Plenty of water, the palm of your hand and your fingernails.

Question 14

Best thing to remove bugs on your windshield?

Answer 14

At DAWN, dew will begin to form on the windows.

Question 15

products containing ______ are extremely damaging acrylic plastics. (Windex)

Answer 15

Ammonium

Question 16

Are you allowed to use standard metal or wood cutting drill bits?

Answer 16

Fucking NO, you will risk chipping or cracking the material.

Question 17

Grind the tip angle (usually a relatively flat ___-___) to a sharp 60⁰ - 90⁰ This sharp angle allows the bit to easily enter and exit acrylic sheet without chipping.

Answer 17

118⁰ - 120⁰

Question 18

Always drill _____ holes to allow everything to move around.

Answer 18

oversized/larger

Question 19

Never drill holes in ______ process. Start with smaller hole and work way up to finish size.

Answer 19

One

Question 20

Largest hole you should drill in one step is _____?

Answer 20

1/4” (0.250”)

Question 21

Using ______ may help you accomplish smaller holes to finish size holes.

Answer 21

Step drill

Question 22

ATA chapter for Window Damage limits?

Answer 22

ATA 56

Question 23

Always remember to find the ______ of the scratch before working on it.

Answer 23

deepness

Question 24

Which sandpaper is coarser? 400 or 800?

Answer 24

400

Question 25

Water also acts as a ______ to prevent acrylic plastic from being overheated.

Answer 25

coolant

Question 26

When sanding with the finer abrasives, cross your sanding pattern at _______ degree angles from one step to the next, to be sure of total removal of previous sanding pattern.

Answer 26

90 degree

Question 27

When cutting plastic windows. Never use a saw that has a _____ blade.

Answer 27

reciprocating use a BAND saw instead

Question 28

When trimming acrylic plastics to FIT IN A GIVEN AREA, the fine detail work is best accomplished through the use of a small hand held 90⁰ ________ equipped with a small sanding disc with a 80 grit or 100 grit pad.

Answer 28

die grinder

Question 29

In the case of a crack, all of the ends of the crack can be stop-drilled with _____ drill bit.

Answer 29

#30 (0.1285" or 1/8")

Question 30

Permanent repair can be made to acrylic plastic by using a _____ such as PS-30 or weld-On and a hypodermic syringe.

Answer 30

"Polymerizable cement" such as PS-30 or weld-On and a hypodermic syringe.