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Rob's REBVAIR Project
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Date:  9-30-2013
Number of Hours:  5.00
Manual Reference:  
Brief Description:  Forward 'eyebrow' skylights (part 1)

Given the imminent work on the panel, I decided I wanted to get the skylights out of the way given the mess they would create. I took a recommendation from the MurphyBuilders site and re-appropriated an old fus- (0.020") as pre-curved stock for eyebrow window doubler material. I sandwiched two flanges together to acheive a 0.040" thickness. After carefully laying out where it would go, I laid the doublers down over the location and drilled the center-line holes first (along the center of the 'long' part of the flange) along the roof line. Doing it this way pulled the curved material up close to the roof material and kept things in position while the rest of the holes were drilled (Image 1). Several folks have complained that using flat material here resulted in a flatening of the curvature of the roof after the skylight was cut out. I was trying to avoid that with this procedure.

Image 2 shows the completed doubler, removed but still clecoed together, and the holes on the upper half of theopenign on the roof have been dimpled to avoid any interference with the windshield installation.
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Two 0.020

Two 0.020" doublers clecoed together

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Drill pattern and dimpling

Drill pattern and dimpling

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