The customer who required these had borrowed a couple of old ones from a friend, so I could use them for patterns. Firstly an average measurement had to be taken across the mounting holes. Then the screen was laid on a sheet of stiff paper and the profile was marked, including the glass for reference. A complete drawing had to be done as the borrowed screens had to be returned to their owner.
The next step was step was to manufacture the channel that the glass was to be held in by. This type of channel is not availabe of the shelf and so I had to make it. The profile was formed on a set of hand operated rollers. Once all the constituent parts had been made I then had to join them together. To do this I laid the parts on a surface plate and tack welded using the TIG welding process. The windscreen channel shape was now formed and I then needed to solder the whole construction using oxy-acetylene. After the soldering was completed it was finely fettled and de-burred to give a smooth finish, ready for chrome plating. The glass was the final thing to be fitted before it could be put on the car. The pictures show the screens fitted to the car. Each screen is held on by two polished stainless steel acorn headed screws.
