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Date:  6-13-2021
Number of Hours:  4.20
Manual Reference:  18-05
Brief Description:  Cutting turtleback windows

Made a cutting template from aluminium flashing and marked up remaining bubble half. Did the full Zach-endorsed Glastar thing and taped up the cutline, remarked the cutline, and cut out the bits with a 4" grinder with a thin metal blade. Marked up for 2 spare rear windows directly onto the glass, and the cut exactly the same as the previous. Hmmmmmmm. Tape may be a woftam.

Whilst wondering what to put these windows on for trimming, Viki, (light of my life), wandered into the shed clutching a de-commisioned doona cover and two sheets, asking if I had a use for them. You bewdy!

Trimmed all resulting windows with the Zach-approved 4" 40g sanding disc on my angle grinder, and it goes brilliantly.

Did the Glastar thing, and marked cutlines to fit in the available windows with a fine water-based marker, sanded to the line, wiped it off and remarked until all the windows fitted. This means they are all about 3/16" oversized, which is fine by me. Precision profiling will happen after paint.

A smart man would have photographed the windows in place. Guess I'm not a smart man...

I can't find any spraylat locally, so covered all the windows with some film I found at Bunnings Aerospace. It will need to be removed within 60 days. This stuff had been on the inside of the main canopy for 50 days, and the old stuff seemed to peel off exactly the same as the new. I marked them all with the date, and will run some test bits on the smaller windows to see if it deteriorates in time. Heat may be a factor.
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Marking rough cut for windows

Marking rough cut for windows

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Trimmy, trimmy. Tremenous mess

Trimmy, trimmy. Tremenous mess

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Protecting the lovely glass

Protecting the lovely glass

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