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Rob's REBVAIR Project
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Date:  10-5-2016
Number of Hours:  6.00
Manual Reference:  
Brief Description:  Windshield Install Part 7: install sequence part 1

So with all the edges of the windshield trimmed and sanded with 120 grit paper, all the metal surfaces scotch-brite sanded for adhesion, and all the surfaces to stay clean masked-off, the final sequence I followed goes like this:
1) Apply 5/8"x 1/8" butyl tape on the top and sides of the windscreen as per manual, but do not remove the protective film. This will allow you to take the time to properly position the windscreen.
2) Position windscreen on fuselage and cleco front retainer into position. For a water-tight seal, contact between windshield and the front retainer is critical, so I wanted it there as a 'rest' to push against while I fiddled with it elsewhere.
3) Align 'witness' marks where the top of the windshield rests close to fuselage. When both sides of the fuselage are correctly aligned, lift the top of the wndshield just enough to be able to remove the protective film on the butyl tape, ensuring the windshield doesn't move. Then allow the windscreen/butyl tape to stick to the fuselage and only press down slightly at this point.
4) Apply 3M glazing compound to the area under the retainer (around rivets) and cleco the top retainer in place with medium pressure to squeeze out excess compound.
5) With the front retainer still in place, move to the left side and pull the film off the butyl tape as in Step 3. Before setting the windshield side onto the fuselage side (holding with left hand) reach inside with your right hand and push the front of the windshield against the front retainer to make sure it is still in close contact. When satisfied, drop the windshield/buyl tape onto the fuselage and press lightly (for now).
6) Apply 3M glazing compound to left side retainer and cleco in place as in Step 4.
7) Repeat Steps 5 and 6 for right side.
8) Now remove the front retainer and apply butyl tape, as well as 3M compound to the fuselage around rivet holes.
9) Lay the retainer into position (takes two people) being careful not to smudge anything. Use a punch to align, then cleco.
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removing tape once windshield correctly positioned

removing tape once windshield correctly positioned

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3M glazing compound beads

3M glazing compound beads

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butyl tape, plexi, 1/16

butyl tape, plexi, 1/16" weather-stripping, retainer

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