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Builder:
  David Macdonald
Location:
  Sugar Land, TX - USA
Aircraft:
  RV-10
Total Build Hours:
  1328
Web Site:
  http://www.mykitlog.com/DaveMacdonal/

Date:  08-22-2017
Number of Hours:  6.25
Short Description:  Preparing for Gluing Plexiglass

Prepared the plexiglass windows and associated mounting locations for gluing the plexi in-place.

Placed each window into its location on the fulelage or door. Using a Sharpie I traced the mounting flange edges onto the plastic covering on the outside of the plexi. Removed the plexi, turned it over, and peeled back the plastic covering on the inside to about 1.5 inches beyond the traced flange line. Carefully trimed this plastic covering off with a box cutter and smoothed the remaining plastic back down to the plexi.

Used Scotch 35 electrical tape to mask the plexi with the outer edge of the tape matching the flange line previously drawn. Then added 1.5 inch painters tape to cover the area of the plexi between the electrical tape to beyond the edge of the plastic covering that was trimmed. Sanded the resulting bare plexi that will be glued using 220 grit wet/dry sandpaper.

Place each window back into place, and determined areas that require shims to raise the edge of the plexi to approximately flush with the fiberglass joggle at the mounting flange. Marked these points on the outside of the joggle using a Sharpie. Removed the window and sanded the mounting flange using 220 sandpaper, being careful not to remove the marks for the shims. Cleaned up he sanding dust from the flanges using alcohol on a paper towel.

Mixed up a small amount of epoxy and used a small brush to apply a light dab of epoxy at each location previously marked for shims on the doors with the mounting flanges approximately horizontal. Then set an AN960 - 8 washer onto the epoxy at each of the shim locations. Cleaned up any excess epoxy using a paper towel.

For the rear windows, I mixed up a small batch of epoxy with Cab-O-Sil to a peanut butter consisteny. This epoxy then held to the vertical flanges of the rear window mounts and held the washer shims in place.

Left the shop for the day. Next step will be gluing the plexiglass windows in place.
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