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Steves S-20 Build Site.
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Date: 4-7-2019
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Number of Hours: 6.00
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Manual Reference:
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Brief Description: Fit up the skylight.
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To fit up the skylight I followed the manual to make the two strips which join the skylight to the windshield. I did this working on the floor to provide a flat surface. I also created the rib strips pre the manual. Then I deviated from the manual slightly and measured and drilled the lexan skylight for the rib strips, which would later be drilled into the centerlines of the rib tubes.
In theory, or at least in my head, this should have worked well, but when I put the windshield / skylight assembly back on the plane, the rib strips and holes I had drilled did not light up with the ribs - Ugh!! After pondering this for a bit I realized that when I put the windshield in I started off trying to get everything perfectly centered, but then decided that fit was more important, so I adjust the windshield for best fit, which resulted in it being turned just a tiny bit. This degree of so of turn does not show up until you attach the 4 feet of skylight and try to line up the predrilled holes with the ribs.
I ended up cleckoing just the left corner, then adjusting the skylight for best fit. I found that the outside ribs were about 1/4" wider at the rear than the front, so I made up some 1/8" spacers to insert between the factory tab and the extensions I had made at the rear of the ribs. I was able to get it all lined up, and everything is true and straight except the seam between the windshield and the skylight, which is tight on the left side with about a 1/4" gap on the right side. This is covered by the joining strips, except for a couple of the holes I had drilled for the joint strips. I have some aluminum on the way to increase the width of the joint strips and cover up the exposed holes and finish up the skylight.
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Drilling all the holes.
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A Weekends worth of progress.
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