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dlm46007(at)cox.net
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 Posted: Fri Apr 14, 2006 8:22 am Post subject: Windows |
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Pictures to follow later today
window procedure
Although the procedure takes only about an hour to accomplish per window, setup and planning is substantially more.. I recommend that you do one window to get the procs correct and plan to do the windshield on a day by itself.
(0) tape off the inside and outside flange area of the window using 3M Fineline (.5 width)
(1) then signstrip blue on the center areas to protect the inside and outside of the window . Be generous when painting it on as this makes it easy to pull off.
(2) sand the inside/outside edges of the window in the area of the flange to roughen the glass for adhesion.
(3) sand the flanges of the lid; CLEAN ALL SANDED EDGES WITH ACETONE
(4) prepare a set of aluminum "fingers" . Strips of .080 1" by 3" ; with a slight bend in the center. one end gets a #30 hole and the other is adequately taped. each is numbered. See the picture.
(5) Trim the window to fit the frame and temporarily hold in place with the NUMBERED "fingers". Clecoes should be place about .50" outside the window. Drill #30 only through the external layer; NOT THROUGH THE LID. RETAPE OFF THE EDGES 3M FINELINE TAPE .
(6) prepare a mixture of epoxy with chopped fibers and cabosil. Consistency should be peanut butter. Potlife should plan to be 30-40 minutes. We refrigerated it to further slow the cure.
(7) putty the lid flanges, wet the window flanges with a small amount of catalyzed epoxy and place window in frame; holding in place with "fingers" at the preplanned locations.
( inside person should be wiping excess putty away with a 50-50 mixture of mineral spirirts and acetone; outside person should be smoothing putty on outside flange. excess will be sanded off later. then PULL THE TAPES BEFORE IT CURES.
(9) allow to cure 24 hours.
(10) Inside lid , flange should be finished . If rough, tape glass and sand lightly.
(11) outside the lid, RETAPE the edge at the flange line, then cover the flange with two 1" layers of glass (E-7782?). (Note this was the Glastar procedure.) Remember to pull the tape before the layered glass sets up. The windscreen on the RV10 requires a different layering of glass on the aluminum.
(12) Retape the edge , then sand and fill external flange area for paint. The sanding can feather into the edge of the tape.
(13) when painted , paint should cover the flange.
(14) MUST BE DONE BEFORE THE MIXTURE CURES. If you accidentally get epoxy on the Plexiglas during the process, it can be safely removed using a clean cloth and the 50-50 mixture of mineral spirits and acetone. Have it handy.
(15) 50-50 mixture is also good for removing any signstrip that does not come off when finally removing the protective covering before flight.
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dlm46007(at)cox.net
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| Posted: Fri Apr 14, 2006 8:25 am Post subject: Windows |
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DO NOT FORGET TO PUT VASELINE ON THE CLECO TIP FOR EASY REMOVAL
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dlm46007(at)cox.net
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| Posted: Fri Apr 14, 2006 9:20 am Post subject: Windows |
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pictures
| | - The Matronics RV10-List Email Forum - | | | Use the List Feature Navigator to browse the many List utilities available such as the Email Subscriptions page, Archive Search & Download, 7-Day Browse, Chat, FAQ, Photoshare, and much more:
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jesse(at)itecusa.org
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| Posted: Fri Apr 14, 2006 2:46 pm Post subject: Windows |
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We used a very similar method, but used screws to hold the clips to keep them tight and used FE6026 Part A & B from Spruce as the glue. It was recommended to us by a guy who builds Lancairs and it seems to hold really well. We just filled around the edges with epoxy and micro and have not had any cracking after 200+ flying hours. No e-glass, but it wouldn’t hurt. Just would take a lot more work to get faired into the windows well.
Jesse Saint
I-TEC, Inc.
jesse(at)itecusa.org (jesse(at)itecusa.org)
www.itecusa.org
I'm in Ecuador right now and should be back in the country by the end of May. You may call me at 352-505-1899 and leave a message that I can check from down here. Any I-TEC questions can be directed to the I-TEC office at 352-465-4545.
From: owner-rv10-list-server(at)matronics.com [mailto:owner-rv10-list-server(at)matronics.com] On Behalf Of David McNeill
Sent: Friday, April 14, 2006 11:21 AM
To: rv10-list(at)matronics.com
Subject: Windows
Pictures to follow later today
window procedure
Although the procedure takes only about an hour to accomplish per window, setup and planning is substantially more.. I recommend that you do one window to get the procs correct and plan to do the windshield on a day by itself.
(0) tape off the inside and outside flange area of the window using 3M Fineline (.5 width)
(1) then signstrip blue on the center areas to protect the inside and outside of the window . Be generous when painting it on as this makes it easy to pull off.
(2) sand the inside/outside edges of the window in the area of the flange to roughen the glass for adhesion.
(3) sand the flanges of the lid; CLEAN ALL SANDED EDGES WITH ACETONE
(4) prepare a set of aluminum "fingers" . Strips of .080 1" by 3" ; with a slight bend in the center. one end gets a #30 hole and the other is adequately taped. each is numbered. See the picture.
(5) Trim the window to fit the frame and temporarily hold in place with the NUMBERED "fingers". Clecoes should be place about .50" outside the window. Drill #30 only through the external layer; NOT THROUGH THE LID. RETAPE OFF THE EDGES 3M FINELINE TAPE .
(6) prepare a mixture of epoxy with chopped fibers and cabosil. Consistency should be peanut butter. Potlife should plan to be 30-40 minutes. We refrigerated it to further slow the cure.
(7) putty the lid flanges, wet the window flanges with a small amount of catalyzed epoxy and place window in frame; holding in place with "fingers" at the preplanned locations.
( inside person should be wiping excess putty away with a 50-50 mixture of mineral spirirts and acetone; outside person should be smoothing putty on outside flange. excess will be sanded off later. then PULL THE TAPES BEFORE IT CURES.
(9) allow to cure 24 hours.
(10) Inside lid , flange should be finished . If rough, tape glass and sand lightly.
(11) outside the lid, RETAPE the edge at the flange line, then cover the flange with two 1" layers of glass (E-7782?). (Note this was the Glastar procedure.) [b]Remember to pull the tape before the layered glass sets up.[/b] The windscreen on the RV10 requires a different layering of glass on the aluminum.
(12) Retape the edge , then sand and fill external flange area for paint. The sanding can feather into the edge of the tape.
(13) when painted , paint should cover the flange.
(14) MUST BE DONE BEFORE THE MIXTURE CURES. If you accidentally get epoxy on the Plexiglas during the process, it can be safely removed using a clean cloth and the 50-50 mixture of mineral spirits and acetone. [b]Have it handy.[/b]
(15) 50-50 mixture is also good for removing any signstrip that does not come off when finally removing the protective covering before flight.
| | - The Matronics RV10-List Email Forum - | | | Use the List Feature Navigator to browse the many List utilities available such as the Email Subscriptions page, Archive Search & Download, 7-Day Browse, Chat, FAQ, Photoshare, and much more:
http://www.matronics.com/Navigator?RV10-List |
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