Finish Kit

Window install  ( 4 hrs )

Finished Machine C'sinking holes along Fwd edge (at Roll Bar), and sanding same edge with 220 then 400 grit.  Worked very carefully, so consumed a lot of time.   I decided to hand file a chamfer on trailing edge of window shim on Roll Bar.   The Roll Bar ( essentially a rectangular tube) does not twist as it goes from top surface to vertical surface.  Consequently, the window shim surface doesn't align w/ plexiglass by about 5 degrees.  Tightening the screws holding the plexiglass will put a bend in the first 1/2"...so I've attempted to minimize that stress.     Test fit -- overall, looks great ...and very pleased NO cracks...Yahoo!  It's been a tense week working on the Window...so glad done with Sect 38-03.

shiny surface is new "chamfer" on window
shim.  Needed some touch up paint anyway.

close up of fit

 

Finish Kit

Rear Window  ( 5 hrs )

Completed enlarging holes to #27 size in plexiglass.  Also drilled #27 holes in Fuse Skins, deburred, "broke" edges, then dimpled.  Sanded edges of plexiglass along aft edge with 220, then 400 grit per Step 11 & 12 in Sect 38-03.    Machine C'sunk Window for .025" dimpled skin (slightly deeper req'd vs screw head only).

To dimple skin above Roll Bar Brace,  needed to use parts from C-frame.

Access hole in Brace allowed access from underneath -  my Main Squeeze

 from Cleaveland Tools would not work there

Edge sanded smooth, and Mach C'sunk for dimpled skin...

Finish Kit

Rear Window drilling, etc ( 5 hrs )

Completed Step 4 in Sect 38-03 by tapping for 6-32 screws in Roll Bar.  First drilled #36 holes through plexiglass and Roll Bar.  Vans instructs to tap next, but I removed the plexiglass (after trying one).   Since plexiglass gets drilled w/ larger #27 drill immediately as clearance hole, seems risky to tap the plexiglass.    Had no trouble aligning the tap without plexiglass.   Used Boelube on tap.   Drilled remaining holes w/ #36 bit (dulled for plastic) - and deburred/chamfered each hole at top and bottom (advice on VAF forums to reduce cracking risk).   Kept plexiglass warm with halogen lights, a few degrees above 83 deg shop temp.   Then proceeded with Step 8 final drill w/ #27 bit (screw clearance holes).   No cracks.   Still have about 24 holes to final drill...then machine countersink for flat head screws or dimpled skins.

tapping w/o plexiglass window

close up of tapped hole on Roll Bar

warming plexiglass during final drilling to #27 size

example hole chamfered.  Next add
machine countersink for flat head screw

Finish Kit

Window drilling  ( 3 hrs )

Cont'd drilling per sequence #1 thru #10 for LH and RH sides.   Finished all #40 holes except final 2 holes each side.  No cracks so far !  Garage around 83 degrees is helping.   Nancy again crawled back into baggage area to hold wood block supporting plexiglass as I drilled.   This time I snapped a pic.

 

No clamps needed now. 

Finish Kit

Canopy and Window  ( 5 hrs )

Started Sect 38-02  Canopy and Window installation per Finish Kit.  Took my time with some practice drilling in scrap plexiglass using my newly "dulled" #40 drill bit (also prepped #36 and #27 bits.  Keeping the shop around 80 degrees, and proceeding with light force seems to be working - no stress crack so far.   Cut clearance notches at aft edge using dremel with small drum sander.   I positioned, re-positioned, then re-positioned again the window until aligned just right along Roll Bar. Then Nancy climbed into baggage area to hold wood block behind plexiglass as I drilled from outside.   She's quite a "trooper".   First 9 done -- whew !   Forgot to take pic with Nancy in position, but will next time when we hopefully finish drilling.

First fit up, with 12/32" extra on Roll Bar  - until I cut in notches on rear edge

Success so far....first 9 holes.

Other clamps kept slipping.  These work great.

Notched more than necessary at Roll Bar Brace flange.  Had to
add small clearance for rivet (near center of this pic)

Finish Kit

Inventory Completed ( 4 hrs )

Finally completed inventory - sorting, counting, labeling, organizing.  Vans Aircraft only missed count by 1 on 3 items, and provided 426 flush rivets instead of 470 universal rivets in one bag.   Seems about 99.5% accuracy, since 9 pages of items listed.  Whew...I'm ready to start building again.

Finish Kit

More inventory ( 2 hrs )

Took friends flying for their first time in morning...beautiful weather (unseasonably mild for Aug in midwest!).  Then back to inventory.  Getting close to completing - approx 10 bags to go.

shelves are filling up

mostly nosegear

the large pile of bags is down to only 10 or so left....