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CHUCK'S WEB SITE
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Date: 6-11-2022
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Number of Hours: 5.10
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Manual Reference: SNB-D03
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Brief Description: Windshield Installation
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Spent quite some time trying to understand the plans instructions for installing the windshield. I inserted the skirt first, then located and drilled the left and right front lower holes only. Clecoed these two holes to begin the fitting.
Next the windshield is to be inserted, but this is much more difficult/akward than you would think. As the windshield is inserted and moved, the pressure from this lifts the skirt out from between the fuselage skin and the longeron in the aft portion. It would really help to have the sides of the skirt clecoed in place, but I interpret from the plans that these are to stay unclecoed to allow "fitting". I believe the skirt is to be inserted between the fuselage skin and the longeron to a depth of 1" the full length on each side, but this is not specified, only assumed from the 1" vertical rear edge on each back corner of the skirt. This 1" vertical edge then angles forward for the arched rear band portion of the skirt.
As I roughly positioned the windshiled skirt, I could see the canopy (installed during the quick build) forward edge was significantly overlapping the windshield skirt rear edge. Upon closer inspection, I fould the canopy acrylic material extended past the forward canopy bow by 3/16" more than the specified 1/2". This means the windshield cannot be installed to have the specified 1/16" gap between the rear edge of the windshield skirt and the leading edge of the acrylic canopy material.
I am not continuing until talking to Kerry at Sonex about this. My assumption is because this is a quick build, the factory installed and fit the canopy before the windshiled was installed. I believe it would ordinarily be done installing the windshield first, then fitting the canopy to both the windshield rear edge and the turtledeck front bulkhead edge. Since the factory didn't have a windshield to fit to, I am assuming they left extended material there for the owner/builder to be able to fit it to the windshield when it was installed. I am assuming I need to
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Positioning windshield skirt for front left lower hole alignment.
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Preliminary insertion of the windshield under the skirt with front two forward lower holes clecoed.
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Forward edge of canopy completed for the Quick Build.
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