Hot Rod Windshield needed

[DonC]

16245Anyone have a windshield for sale?
Just opened my box and found a crack in the frame at one of the two weld sites...being that the unit is outside of factory five's 45 day replacement policy was told to basically stuff it.
Any and all help appreciated.
Don

Not getting any help from FFR on this one so I thought it necessary to take the frame apart to see what I was up against and sure enough the weld just fell apart in my hands...worst penetration I've ever seen.

The frame is basically made using Sand Cast Aluminum Corners that are then welded to Extruded Aluminum cross members to make up the assembly. The top and bottom halves are then screwed (properly) together facilitating a means to remove and replace a damaged glass section. If only they had used the same mechanical attachment method VS1625316254 the crappy welds we would all have been better served.

I'd hate to imagine a high speed in-situ failure and what that might cause...not pretty.
So fellow current and potential 33 hot rod owners inspect your windshield frames with a magnifying glass when you first receive your shipment as this might happen to you too...it has blown my doors off!

Don

[michael everson]

I would call them back and explain the situation to someone else.
Mike

[DonC]

Michael,
Any recommendations as to whom to speak with...all I have thus far is their policy and that the material is Sand Cast Aluminum. I sure can't take that to a welder with any confidence of the outcome...really need the exact material spec's first as this material may not even be weldable or heat treatable. Was really expecting more from the FFR guys...it's like pulling teeth from a gator.
I'd even be willing to buy just the frame at this point.
Don

[Tom Veale]

Hi Don, Re: Broken windshield frame..................

We dis-assembled my front windscreen and removed the glass for priming and painting. We went to re-assemble it and the spot welds broke on the bottom "U" on both sides. Poor weld penetration turned out to be the cause. (please remember that my chassis # is 007) The break almost looked like it had been sawed with a fine blade and then superglued instead of welded.

We bevelled the edges on adjacent pieces and welded it back together. It worked fine. Of course then we had to repaint it, too.

The top inverted "U" is constructed the same way, but those welds never cracked.

http://thefactoryfiveforum.com/attachment.php?attachmentid=16272&d=1363706310

http://thefactoryfiveforum.com/attachment.php?attachmentid=16271&d=1363706288

After repair, there was no evidence the problem ever existed.

The guy who did the welding did a great job.

Best regards, TV

[DonC]

TV,
Thanks for your input...I felt as if I was the only one that had experienced this particular failure. It would be great if any other builders/owners would come forward so as to add the power of legitimacy to my FFR claim that they need a design change.

Anybody out their reading this and having or had similar problems please send me an email: dcampbelljr44@att.net...I'm now building my case but only with your help.

TV...many thanks and glad your repairs were successful. I'm off today to try and get mine fixed as well.
BR
Don

[David Hodgkins]

Don, what number is your chassis and when did you buy the kit from FFR?

:)

[DonC]

Hello Dave,
The chassis number is 135 with date of manufacture 2009.
BR
Don

[David Hodgkins]

So the windshield is 4 years old. Did FFR offer any discount on a new windshield? Did you buy the kit from FFR?

Not trying to pick on you, just gather all the facts so I can relay info to FFR. I hope between you, the forum and FFR that a satisfactory resolution can be worked out.

:)

[DonC]

Dave,
Appreciate the time you are giving this issue as well as the spirit of your inquiries. Yes my windshield kit is 4 years old and was purchased from FFR. Having gone around a few times with one of the FFR Technical Salesmen has resulted in them offering a $250 discount on a replacement windshield assembly. That is more than I every anticipated or expected from FFR as the issue is about a bad design. I initially just asked (via email) if FFR could help me resolve the crack that I discovered. I know a bad design when I see it and that is mission with them...get that butt weld process replaced with something stronger....a mechanical joint would serve us all better. There are several sound ways of joining the cast and extruded pieces together that would not break as these welds are prone to do.
Our goal within the next year is to start building these FFR hot rods and I want them to be the best they can be. So with that said I personally have a vested interest in having FFR look into this manufacturing flaws such as I encountered and correcting them before shipments. I'll make the assumption that FFR has this windshield manufactured by a vendor and if that is true then the joinery process is out of control. In my engineering world a visible structural flaw like Tom Veale's or mine should not have passed Q/C...I trust you would agree.
BR
Don

[kemper.s@sbcglobal.net]

did you solve this? I have a windshield