Rear Windows

[Steve W]

For Brooks and others interested, I used Sitka spruce for the fuselage side formers and related parts. Baltic birch plywood was available locally and used 1/4" for the main frame and 1/8" for the outside layer/plexi recess or sill. Lots of quality structural glue. The whole assembly was done on the fuselage to align "flush" the sides, formers and door sills. I like wood because it is very forgiving and easily shaped. It gave a good platform to attach the light inside dacron to and later on, the side fabric. After the covering process was done, the .080" plexi was glued in with Silpruf 2000. Same stuff used to install all the windows in a Glastar. The sill or recess the plexi lays in is about .125" deep so a bead of cured Silpruf is cut very thin (about the size of a dime and tacked on with Silpruf every 6" or so). These are used as "stand-offs" to bring the plexi flush with the sides and allows for the adhesive to remain in the joint for strength. After this cures, tape off the void around the frame and plexi and fill it with Silpruf and tool. I'll try to locate some inside/outside pictures and post them.
Steve P203

[Steve W]

More Pictures

[Steve W]

One more. Windows need cleaning

[Bdflies]

That’s a great idea and some really nice work!

Bill

[Bcone1381]

Thanks Steve! Thirty one clamps used in the first photo puts a new meaning to "You can never have enough clamps." Your interior really looks great too. I had thought about the shelf that you have too. A great place to put hats, coats, and the sack lunches.

I am interested and curios in your hinged front side window. That looks real clean and has a lock. How did you mount the Plexi onto the frame? The Kit uses round tube for the window and door frame. It looks like you scratch built your Fuselage, so maybe different material for the widow frame. It looks to me like your Plexi is cut oversize and forms seal with the fuselage. That lock has me curious too. I look at a lot of window install application at every Oshkosh. The Carbon Cub EAB kits have a similar look. I just dont yet know how to make it work with the round tube frame of the Patrol Kit, but I'm leaning towards a composition resolution. Wondering now how some wood might be part of the solution.

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[OhioLSA]

Really nice work, Steve!

[Steve W]

Thanks for the comments guys, appreciate it. I felt the doors and windows were about the hardest parts to do with very little information provided or found. The front side windows were fitted/hinges welded to the fuselage after the wings were mounted. I also welded in a small 3/8" tubing in the upper joint to fill the gap and allow some weatherstripping to come against the window when it was closed. I layered up my windows differently and was concerned about clearing the underside of the wing root fairing. I used .080 plexi sandwiched between the 3/4" round frame and the outer aluminum sheet. The rivet line has to be centered on the "round" or will not lay flat. I used Lexel between the plexi and the aluminum and placed a bead of Silpruf between the plexi and the tubing. When cured, this would help shoulder the area around the holes in the plexi. Holes were previously drilled/dimpled/countersunk and was clecoed together and allowed to cure. I used very soft CC pop rivets trying not to place any strain against the materials.
The lock is just a "throw" against the inside lever. I welded up brackets on the 3/4" tube to hold the lock in the right position. I'll try and find a picture.

[Bcone1381]

That really helps and turned out very nice!