Window Resin Retrofitters
Bulletproofing your windows
Team: Ammon Houser, Kyle Hilton, Lauren Baer, Will McQueen
Project Goals
- Develop a nonintrusive method to fill existing dual pane windows with a bulletproof resin
- Create a mobile unit that can be brought into a building and used to inject resin into window cavities
Ballistic Testing
- We tested the resin panels using 9mm FMJ rounds
- Panels withstood 3 shots before failure
Three Subsystems
Transportation and Pump
- A 50-gallon-drum dolly was modified to transport resin and pump
- A peristaltic pump was selected to prevent resin from seizing up the pump
Window Access
- Designed drill jig with a Digimatic scale to drill precise hole in window frame
- Jig is fastened to window frame and hole is drilled just above the top of glass
- Dremel is placed in jig allowing accurate depth measurement to avoid damaging glass
- Dremel cuts downward to open access hole
System Testing
- Used aluminum plate to simulate window frame
- Used the jig system to successfully cut access hole in the window spacer
- Inserted a 1/8 “ tube into the access hole
- Turned on pump and filled the window with water
Conclusions
Lessons Learned
- Used 1” diameter bits, but didn't account for odd shape of Dremel wheel
- Tube should be purged of air bubbles before going in window
- Tube curls up inside window and is difficult to aim
Moving forward
- Increase the bit diameters or use the expanding rotary cutter design shown below
- Place metal rings on the tube and use magnet to guide
