With my Dad staying with me I haven’t had the chance to do timely updates but over the last couple of weekends I’ve been in the hangar with both him and Allen working on the windscreen and the doors.
There was a LOT of grinding and filing on the windscreen to get a better fit at the top of the cabin and on the sides. But we finally got it where it seemed like it would work. There’s a top channel piece that rivets to the top window and screws to the windscreen.
Note that I drilled the holes on the windscreen side too big, only the plastic is supposed to be that large. The screws still work with it though.
After the holes were drilled into the plastic, a change of drill bit was used to carry on into the cabin frame. We did a poor job of getting the angle right but Allen got it to where the screws will go in and keep it all on. That said, I need to buy longer screws.
The sides of the windshield slot into a metal trim piece which is then screwed into the cabin frame.
Every hole drilled through the plastic was a nervy one but so far at least no cracks.
With the side trims held in place we can measure the hinges for the doors. Cut the hinge to the right size, drilled a line of pilot holes and back drilled into the rib.
The hinge pin gets bent so that 3mm of it is outside of the hinge.
Then reassembled the hinge with the other half, already drilled.
Next my Dad and Allen held the door in position while I looked from the inside to get the best fit. After some jiggling around I marked some pilot holes with a pen, remove the door and hinge and back drilled into the door. Then back on for a look.
Repeated the same process with the passenger side, here’s a view from the inside.
The doors are both too large for the fitting and need to be trimmed, we marked the trim points but did not have the appropriate cutting tool and so that was it for this trip to the hangar.