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Project Blue Angels SeaRey
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Date: 4-3-2013
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Number of Hours: 4.00
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Manual Reference: 20.1 -20.3
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Brief Description: Began section 20, turtle deck final assembly
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Began section 20, turtle deck final assembly, cutting the cabin windows. I actually was going to skip this section and work on the turtle deck bulkhead arch support, because I couldn't stand the thought of cutting into my new paint job yet, but when I began with the arch, I figured out that I could really use a big hole there to reach the drill through, so a cutting I went. This was nerve-racking, with a $10k paint job. The manual says to cut these after painting, so no overspray gets in there, but I would much rather have just cut before, and trusted that the paintshop knows how to protect for overspray.
After I made the window template, and marked where to cut with a dry-erase marker, at least I had the bright idea to use masking tape outside the area to cut, to protect the paint, and give me a more defined edge to cut for. Smartest thing I did all day. Good to have this part out of the way.
I got the cutting started with a Dremel cut, just big enough to stick a knife through to cut the carpet and then insert the jigsaw blade. The blade marked "smooth metal" worked best.
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Template placed 3" over, 4" up.
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Painter's tape to protect that paint job.
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There's my hole. Other side turned out even better. The actual window gets installed much later.
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