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Old 01-03-2015, 06:38 PM   #1
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Join Date: Mar 2013
Location: Houston
Posts: 1,659
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Repairing a broken roll bar windscreen tab

Like all roll bar windscreens mine are old enough to have lost most of their plastisizers. That means the release tabs become brittle and snap off if you're lunatic enough to try removing one to clean it. Don't panic, there is an easy and permanent repair. You will need a pop rivet gun, a small diameter pop rivet, a Dremel tool with a metal cutting disc a hacksaw blade and a drill/drill bit that matches the hole size needed for the pop rivet.

First take the broken windscreen and tab and measure out a length of hacksaw blade against it that will be the new spring to hold the tab in place. The length should be long enough to leave 1.5 times the pop rivet diameter back from the break in the plastic tab on each side. This is so the hole you will drill in the plastic windscreen and plastic tab will have adequate edge distance from the break in the plastic for structural integrity. I needed about 5/8 an inch of hacksaw blade to act as a "spring" to maintain this edge distance in the plastic.

Mark the length of hacksaw blade you think you need, and drill a hole appropriate for the pop rivet diameter and plastic edge distance into each end of the length of hacksaw blade.

After drilling, use the dremel tool to cut the hacksaw blade to length.

While holding the hacksaw blade in the proper place on the plastic windscreen, start match drilling a hole to mark its position. Remove the length of hacksaw blade and finish drilling. Check the length of the "spring" making sure its holes line up to about 1.5 rivet diameter on both side of the break in the windscreen/tab. If it's too short, make a longer spring

If it's good to go, place your spring on the inside diameter of the windscreen and pop rivet it in with the rivet gun. The rivet should run from the outside of the windscreen with the long end of the rivet protruding toward the center of the windscreen. Then drill and rivet the broken tab into place the same way.

That's it, you're done. - worked for me anyway!
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