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rv10rob(at)gmail.com
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 Posted: Sun Jun 21, 2009 2:27 pm Post subject: window fitting - gap between flange and plexi |
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I trimmed one of the rear windows to fit. It looks great on the outside, but on the inside there's a considerable gap (maybe 1/16") between the plexi and the window flange in places. Is this okay? Does the weld-on fill this gap, or am I doing something wrong?
Thanks...
-Rob
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Rob Kochman
RV-10 Wings
Woodinville, WA (near Seattle)
http://kochman.net/N819K
[quote][b]
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Bob Turner
Joined: 03 Jan 2009
Posts: 885
Location: Castro Valley, CA
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| Posted: Sun Jun 21, 2009 3:41 pm Post subject: Re: window fitting - gap between flange and plexi |
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I believe the instructions say it's okay to shim this area with washers.
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Bob Turner
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Lew Gallagher
Joined: 04 Jan 2008
Posts: 402
Location: Greenville , SC
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| Posted: Sun Jun 21, 2009 3:43 pm Post subject: Re: window fitting - gap between flange and plexi |
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Hey Rob,
You can try grinding the high spots on the fiberglass lip to seat the window better, but don't go too thin. You can also grind the inner surface of the plexi to make a better fit, but if the outer surface is flush with the canopy, I wouldn't worry about it too much. The Weld-on is tough stuff.
When I used Weld-on on the windows, I put a layer on the fiberglass flange and on the window to ensure a good bond all around. You have to be pretty quick to do this in warm weather as it sets up quickly (it will set up faster in the cup than spread on the surface), but that also prevents runs. Even if you have a tiny gap or two, the fiberglass layer I put over the plexi/fiberglass joint on the outside seals it.
Fun, huh? Later, - Lew
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NOW OFICIALLY BUILDER #40549
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John Ackerman
Joined: 19 Jun 2006
Posts: 130
Location: Prescott, AZ
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| Posted: Sun Jun 21, 2009 6:05 pm Post subject: window fitting - gap between flange and plexi |
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Gaps like yours make the Weld-On work really miserable, especially on a vertical surface. Enough glue to fill the gap will run like crazy and then the gap is not filled. I had to cut my starboard rear window out with a router and start over with a new one.I covered the new window with packing tape and wax near the frame, determined the proper number of washers/shims to set it out almost flush with the fiberglass – very slightly (< 1/32") recessed. I then filled between the window and the frame with very thick West System epoxy using cabosil and high density filler from West system. I held the windows in place with clecoes and bent tabs.
When the epoxy had mostly set, I removed the windows, let the epoxy cure overnight, and cleaned up the mess. This effectively make a good-fitting casting that required only a thin and consistent layer of Weld-On. This procedure was much easier than trying to do it with just Weld-On. It came out nice and was easy to blend to the fiberglass.
Good luck!
John Ackerman 40458
On Jun 21, 2009, at 3:24 PM, Rob Kochman wrote:
[quote]I trimmed one of the rear windows to fit. It looks great on the outside, but on the inside there's a considerable gap (maybe 1/16") between the plexi and the window flange in places. Is this okay? Does the weld-on fill this gap, or am I doing something wrong?
Thanks...
-Rob
--
Rob Kochman
RV-10 Wings
Woodinville, WA (near Seattle)
http://kochman.net/N819K
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rv10rob(at)gmail.com
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| Posted: Tue Jun 30, 2009 9:27 am Post subject: window fitting - gap between flange and plexi |
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Thanks, all... I called Van's and they also recommended building up the flange. It looks like it should be necessary on the top and bottom only. Though annoying, I'm cautiously optimistic it won't be a big deal.
-Rob
On Sun, Jun 21, 2009 at 7:04 PM, John Ackerman <johnag5b(at)cableone.net (johnag5b(at)cableone.net)> wrote:
| Quote: | Gaps like yours make the Weld-On work really miserable, especially on a vertical surface. Enough glue to fill the gap will run like crazy and then the gap is not filled. I had to cut my starboard rear window out with a router and start over with a new one. I covered the new window with packing tape and wax near the frame, determined the proper number of washers/shims to set it out almost flush with the fiberglass – very slightly (< 1/32") recessed. I then filled between the window and the frame with very thick West System epoxy using cabosil and high density filler from West system. I held the windows in place with clecoes and bent tabs.
When the epoxy had mostly set, I removed the windows, let the epoxy cure overnight, and cleaned up the mess. This effectively make a good-fitting casting that required only a thin and consistent layer of Weld-On. This procedure was much easier than trying to do it with just Weld-On. It came out nice and was easy to blend to the fiberglass.
Good luck!
John Ackerman 40458
On Jun 21, 2009, at 3:24 PM, Rob Kochman wrote:
| Quote: | I trimmed one of the rear windows to fit. It looks great on the outside, but on the inside there's a considerable gap (maybe 1/16") between the plexi and the window flange in places. Is this okay? Does the weld-on fill this gap, or am I doing something wrong?
Thanks...
-Rob
--
Rob Kochman
RV-10 Wings
Woodinville, WA (near Seattle)
http://kochman.net/N819K
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Rob Kochman
RV-10 Wings
Woodinville, WA (near Seattle)
http://kochman.net/N819K
[quote][b]
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