I plan on installing the windows according to the method detailed on Youtube video series. IN order to prep for the headliner install I needed to get at least to the ‘ready for glue’ stage. This involved getting the fit as close to perfect as possible. The trim guy wants to install the headliner material prior to my gluing the windows in to make flush trimming easier. The headliner material is called ‘Ozite’ and will be glued directly to the canopy like an automobile headliner. It is about 1/8 inch thick and uniform throughout so a cut edge will not leave any foam showing or need an edge trim piece.
The window install method involves a single #40 cleco width gap all around the plexi to the recess joggle. That is then filled to flush with adhesive after the window is installed. Painting of the fuselage comes up to the edge of the adhesive and does not cover it, so no later cracking. The result looks like an automobile glass installation with a blacked out ring around the transparency. I already had the plexi trimmed to fit in the joggle and only needed a consistent gap. I fabricated a small aluminum guide to attach to a fine sharpie giving a precise trim line.