Brief Description: Drill Rear Window To Rollbar and Aft Top Skin
Drilling the rear window to the fuselage was a little tricky.I made sure the plexiglass was clamped securely to the rollbar. I then used the 1/8" plexiglass drill bit to drill the holes around the rollbar. In this case I had to be very careful to not only line up the drill bit precisely over the #40 pilot holes that could be seen through the plexiglass in the rollbar, but I couldn't drill into the rollbar itself,,,only through the plexiglass. The reason is that the rollbar can only be drilled out to #36 since these holes have to be tapped for the screws since there is no access into the rollbar for washers and nuts. Had to be very careful on both the alignment and depth.I drilled the holes for the aft edge a little differently. Rather than working from the inside of the fuselage and trying to once again "hit" the pilot holes in the skin, I decided to work from the outside and just drill through the aluminum first with the 1/8" plexiglass bit and then into the plexiglass. The only difficult part here was keeping the rear window pushed tight against the top skin while drilling. I clecoed each hole as I went.
Left view - rear window drilled and clecoed to the fuselage
Right view - rear window drilled and clecoed to the fuselage
Aft view - rear window drilled and clecoed to the fuselage
