Decided to remove window and clean smudges. Also opened holes slightly more with a step drill and then chamfered edges by hand with a debur bit. Re-installed window and fit was much better around the holes.
Masked the outside window and turtle deck with electrical tape. Denise taped the inside since my fat butt didn't do so well back there. Covered remaining skin and window areas inside and out. Denise did a nice job on the inside. (step1)
Made popsicle stick tool, added fuel tank sealant to plastic bag, and applied to window/turtle deck intersection. Installed harware and lightly tightened. Spun screws on right side in fuel tank sealant prior to installation. Ran out of AN960-6 washers so substitued 6 larger washers on the left side until more can be ordered. Also ran out of AN526C632R8 screws and am five short on the right side window-to-roll bar holes. Need to order more and install. At least I didn't run out around the perimeter of the window where there is sealant. Smoothed sealant with popsicle stick tool, then removed tape (inside and outside). Very happy with the way the sealant line turned out. Not real noticable and clean, crisp lines on the outside. Kind of jagged and uneven on the inside where the sealant is between the turtle deck and window. Not sure if it bothers me enough to worry about it. (step 2) PAGE 25-06 IS COMPLETE
UPDATE 8-3-2016 Received additional AN526C632R8 screws from Aircraft Spruce. Installed remaning five screws securing window to roll bar.
UPDATE 9-16-2016 Received additional AN960-6 washers from Aircraft Spruce. Removed substitute washers and installed six AN960-6 washers.
