One thing I wanted to do for a long time is make the read D windows. Unfortunately, there isn't much out there to go on as far as shape goes. Also, I decided to go the aluminum frame route for the left window. I have to make something out of AL for the cargo door anyway, so I'm going for it. I got a piece of poster board and made the window shape that I think fits well with the airplane design. Next was to get some .050 5052 AL sheet to form the channels. Unfortunately I had to buy a full sheet and have half left over...oh well. I used a Harbor Freight roller I got way back when that came with a bunch of other tools at an auction. He only roller set it came with was the joggle roller, so I’m in luck! I has to put a radius on the inside steps as I didn’t want to stretch and deform the AL sheet more than necessary.
