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## Repairs 

Whenever possible, replace, rather than repair, extensively damaged transparent plastic. A carefully patched part is not the equal of a new section, either optically or structurally. At the first sign of crack development, drill a small hole with a #30 or a 1 ⁄ 8 -inch drill at the extreme ends of the cracks. [Figure 7-93]  This serves to localize the cracks and to prevent further splitting by distributing the strain over a large area. If the cracks are small, stopping them with drilled holes usually suffices until replacement or more permanent repairs can be made. 

## Cleaning 

Plastics have many advantages over glass for aircraft use, but they lack the surface hardness of glass and care must be exercised while servicing the aircraft to avoid scratching or otherwise damaging the surface. Clean the plastic by washing it with plenty of water and mild soap, using a clean, soft, grit-free cloth, sponge, or bare hands. Do not use gasoline, alcohol, benzene, acetone, carbon tetrachloride, fire extinguisher or deicing fluids, lacquer thinners, or window cleaning sprays. These soften the plastic and cause crazing. 

Plastics should not be rubbed with a dry cloth since it is likely to cause scratches and to build up an electrostatic charge that attracts dust particles to the surface. If, after removing dirt and grease, no great amount of scratching is visible, finish the plastic with a good grade of commercial wax. Apply the wax in a thin even coat and bring to a high polish by rubbing lightly with a soft cloth. 

## Polishing 

Do not attempt hand polishing or buffing until the surface is clean. A soft, open-type cotton or flannel buffing wheel is suggested. Minor scratches may be removed by vigorously rubbing the affected area by hand, using a soft clean cloth dampened with a mixture of turpentine and chalk, or by applying automobile cleanser with a damp cloth. Remove the cleaner and polish with a soft, dry cloth. Acrylic and 

cellulose acetate plastics are thermoplastic. Friction created by buffing or polishing too long in one spot can generate sufficient heat to soften the surface. This condition produces visual distortion and should be avoided. 

## Windshield Installation 

Use material equivalent to that originally used by the manufacturer of the aircraft for replacement panels. There are many types of transparent plastics on the market. Their properties vary greatly, particularly expansion characteristics, brittleness under low temperatures, resistance to discoloration when exposed to sunlight, surface checking, etc. Information on these properties is in MIL-HDBK-17, Plastics for Flight Vehicles, Part II Transparent Glazing Materials, available from the Government Printing Office (GPO). These properties are considered by aircraft manufacturers in selecting materials to be used in their designs and the use of substitutes having different characteristics may result in subsequent difficulties. 

## Installation Procedures 

When installing a replacement panel, use the same mounting method employed by the manufacturer of the aircraft. While the actual installation varies from one type of aircraft to another, consider the following major principles when installing any replacement panel. 

1. Never force a plastic panel out of shape to make it fit a frame. If a replacement panel does not fit easily into the mounting, obtain a new replacement or heat the whole panel and re-form. When possible, cut and fit a new panel at ordinary room temperature. 

2. In clamping or bolting plastic panels into their mountings, do not place the plastic under excessive compressive stress. It is easy to develop more than 1,000 psi on the plastic by overtorquing a nut and bolt. Tighten each nut to a firm fit, and then back the nut off one full turn (until they are snug and can still be rotated with the fingers). 

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