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Jerrys Web Site
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Date: 12-12-2014
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Number of Hours: 6.00
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Manual Reference:
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Brief Description: Aft Windows
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Today, I completed the three aft windows on the right side of the aircraft. I worked to trim and clean the edges on the three frames, then drilled #40 pilot holes on the frames at the drill press with a back stop using 1 1/4 inch spacing. Then, I match drilled from the inside and finally drilled to #30 from the outside. Then, cleaned up primed and turned my attention to cutting the Lexan. The sheet Murphy provided was a 4x8 sheet, so I rough cut out the three windows with a dremel tool and a cutoff wheel, then took them to the bandsaw for the final cut. After some sanding, I found my deburring tool helped to clean up the edges a bit. Finally, I put my heat gun in the vice and moved the windows edges past slowly to finish off the edges. I purchased some 3M window adhesive strip material to install between the Lexan and the fuselage side. It worked well, but at first I put it on too thick. I needed to stretch it out more. It also does not move much so it won't squeeze out as well as I had hoped. That said, I'll go check it tomorrow morning to see if it flowed much at all. Riveting is complete and the windows look good.
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