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Fitting Windows

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Colin K.

Joined: 04 Sep 2006
Posts: 157
Location: Oklahoma

Posted: Sat Nov 08, 2008 10:24 am Post subject: Fitting Windows

When fitting the side windows, now that they are pre-shaped, is it still

necessary to drill and bolt them, or is the epoxy bond enough to hold them

in place after it is cured?



Colin K.

OK

Lightning # 52 under construction.

http://www.mykitlog.com/cojaken

_________________
Colin K.
OK

IFLYSMODEL(at)AOL.COM
Guest

Posted: Sat Nov 08, 2008 10:32 am Post subject: Fitting Windows

Hey Colin: I put mine in with about 6 screws to hold them in place until  the epoxy set up. Then took the screws out and faired them in with filler.

 Lynn Nelsen

  

  In a message dated 11/8/2008 1:24:46 P.M. Eastern Standard Time,  cjk129(at)cox.net writes:

  	  Quote: 	
		  -->    Lightning-List message posted by: "Colin J. Kennedy"    <cjk129(at)cox.net>

When fitting the side windows, now that they    are pre-shaped, is it still

necessary to drill and bolt them, or is the    epoxy bond enough to hold them

in place after it is cured?



Colin    K.

OK

Lightning # 52 under  sp;             (And Get Some AWESOME FREE   find  you for                          -Matt Dralle,    List  e the  es  y                 - MATRONICS WEB FORUMS  =========================



	




AOL Search: Your one stop for directions, recipes and all other Holiday needs.l?redir=http://searchblog.aol.com/2008/11/04/happy-holidays-from-aol-search/?ncid=emlcntussear00000001 ">Search Now.

  [quote][b]

mark(at)flylightning.net
Guest

Posted: Sat Nov 08, 2008 11:32 am Post subject: Fitting Windows

Colin,



Epoxy alone will hold the windows in. When using screws make a keeper that

will hold the window in place and screw through the fuselage, NOT the

window.



Mark



--

n5pb(at)aol.com
Guest

Posted: Sat Nov 08, 2008 4:30 pm Post subject: Fitting Windows

Colin,

 Here's a pic of what Mark is talking about.

 

 Good luck.

 Paul "Bear" Bryant

 

 

 

 

 --

Colin K.

Joined: 04 Sep 2006
Posts: 157
Location: Oklahoma

Posted: Sun Nov 09, 2008 6:08 am Post subject: Fitting Windows

Thanks  Bear. 

  

 Did  you have to trim the windows, and if so, how did you do it?

  

  

Colin K. 

OK 

Lightning # 52 under construction. 

http://www.mykitlog.com/cojaken  

 [quote]   

   --

_________________
Colin K.
OK

pennington(at)q.com
Guest

Posted: Sun Nov 09, 2008 6:29 am Post subject: Fitting Windows

<?xml:namespace prefix="v" /><?xml:namespace prefix="o" /><![endif]-->  Good morning Paul

  

 I cut my windows down with a jig saw to rough size and then used an air  sander to smooth them to final size. 

  

 To hold them in place while bonding them, I drilled 1/8" holes around the  edge and installed Cleco's. See attached photo.

 When the epoxy was almost cured, I removed the Cleco's and soaked them in  Lacquer thinner to remove any epoxy stuck to the Cleco. It worked well for  me.

  

 I've been trying to figure out how to prevent binding and rubbing of the  Rudder cables on the fiberglass stiffener webs at the aft end of the  fuselage. I first tried to install the "U" shaped brackets a little loose so  they would swivel. It helped but did not solve the problem. I ground the  fiberglass away as much as possible but it still rubs and binds up. The  fasteners at the end of the Rudder cables are rigid steel and about 4" long.  They do not flex! There must be a better way to do this. Any ideas?

  

 Have a great day.

  

 Gary Pennington

 [quote]   ---

ryan(at)greenlandings.com
Guest

Posted: Sun Nov 09, 2008 6:33 am Post subject: Fitting Windows

You only have to trim the window a 1/2 inch or so. A belt sander works very well.Ryan GrossGreen Landings Flight Center

Sent from my BlackBerryÂ® smartphone with SprintSpeed

From:  "Colin J. Kennedy" <cjk129(at)cox.net>

Date: Sun, 9 Nov 2008 08:08:25 -0600

To: <lightning-list(at)matronics.com>

Subject: RE: Lightning-List: Fitting Windows

Thanks=20 Bear. 

Did=20 you have to trim the windows, and if so, how did you do = it?

Colin K. =

OK 

Lightning # 52 under construction. =

http://www.mykitlog.com/cojaken<= /A>=20

[quote]   

   --

Clive J

Joined: 03 Nov 2007
Posts: 340
Location: UK

Posted: Sun Nov 09, 2008 6:58 am Post subject: Fitting Windows

There was loads of trimming of the Perspex (or what ever they are made

of) windows on the Jabiru and the Esqual. 

I had best results with a flat 'flap wheel' grinding disc on a 9 inch

angle grinder. Don't know if you have the same kit as we do in the UK. 

Picture of what I used attached. It doesn't grind the plastic to dust

rather comes of in small chips.



Felt pen a line on whilst laying the window in place (make it too big)

then grind till the pen line is gone, then offer up and scribe a new

line, repeat process till it drops in the frame.



Whilst handling windows always make sure it's in a warm place so it's

not brittle, careful the disc doesn't chatter, let the disc do the work,

stroke across the edge rather than push at it.



I bonded my Jabiru windows in with flock, the windscreen cracked on a

mounting screw about 3 weeks later and had to be replaced, boy was that

well fixed in.



Great thing about the Esqual was no screws so no drilling though I

fitted a snap vent in one side which was just about the most stressful

job on the plane (3 1/2 inch hole). I would avoid drilling if you can,

the clamps I've seen on some built logs with holes only in the fuse

would be my approach if I did it again.

Have fun, regards Clive



--

Colin K.

Joined: 04 Sep 2006
Posts: 157
Location: Oklahoma

Posted: Sun Nov 09, 2008 6:01 pm Post subject: Fitting Windows

Thanks all for the advice on the side windows. Both are now successfully

trimmed and one is bonded in place.



I made sure the environment was warm and used a Dremel with a cutting wheel

to trim, and a sanding block with 150 grade to finish the edges.



I made my clamps out of hard plastic and secured the window like in Bear's

photo.



Colin K.

OK

Lightning # 52 under construction.

http://www.mykitlog.com/cojaken



--

_________________
Colin K.
OK

info(at)flylightning.net
Guest

Posted: Mon Nov 10, 2008 7:05 am Post subject: Fitting Windows

Gary,  

   

Ask Tex about his innovation for that.  

   

nick  

         

  

From: owner-lightning-list-server(at)matronics.com [mailto:owner-lightning-list-server(at)matronics.com] On Behalf Of GARY PENNINGTON

 Sent: Sunday, November 09, 2008 8:28 AM

 To: lightning-list(at)matronics.com

 Subject: Re: Lightning-List: Fitting Windows  

  

       

Good morning Paul  

    

   

    

I cut my windows down with a jig saw to rough size and then used an air sander to smooth them to final size.   

    

   

    

To hold them in place while bonding them, I drilled 1/8" holes around the edge and installed Cleco's. See attached photo.  

    

When the epoxy was almost cured, I removed the Cleco's and soaked them in Lacquer thinner to remove any epoxy stuck to the Cleco. It worked well for me.  

    

   

    

I've been trying to figure out how to prevent binding and rubbing of the Rudder cables on the fiberglass stiffener webs at the aft end of the fuselage. I first tried to install the "U" shaped brackets a little loose so they would swivel. It helped but did not solve the problem. I ground the fiberglass away as much as possible but it still rubs and binds up. The fasteners at the end of the Rudder cables are rigid steel and about 4" long. They do not flex! There must be a better way to do this. Any ideas?  

    

   

    

Have a great day.  

    

   

    

Gary Pennington  

  [quote]    

---

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