Vans RV Builders List
Vans Parts Vendors
EAA FAA
Sun n Fun FAA Registry
Oshkosh NTSB
Home Empennage kit Wing Kit Fuselage Kit Finish Kit Power Plant Kit Avionics Paint Interior Home
Home Alterations Vendors Builders Log  Home
Alteration 07 Rear Windows
07.01 Aluminum 07.02 Plexiglass Windows  
Page 07.01 Lay out and cut  Aluminum NOTE: Any alteration will require it to be registered as Experimental-Amateur Built  E-AB
Parts
1 4' X 8' 2024T3 Sheet
1 F-1231B Roll Bar Strap
     

This Alteration will install two small rear windows

 Additional information will be shown in the appropriate section

Step 01: Order 2024T3 Alclad Sheets from Aircraft Spruce.

Builders Note:
I also ordered a sheet of aluminum for the wing tanks to save on shipping cost.
Aircraft Spruce protected the two aluminum sheets between two sheets of 1/2" Plywood.


10/31/14
 
Step 02: 2024T3 Alclad Sheet from Aircraft Spruce in shop.  
Step 03: Use two F-1227R Deck Skins to lay out Aclad Sheet to size.

11/02/14
 
Step 04: Tape and cut to size with a fine tooth Jig saw and file smooth.

11/04/14
 
Step 05: Drill #30 and cleco as you go all holes in the left and right F-1227 Deck skins and not the holes in the center joint.

11/06/14
 
Step 06: Cut off the front of a F-1231B Roll Bar Strap at the hole line and file smooth.

11/06/14
Step 07: Tape the Cut F-1231B Roll Bar Strap to the Roll Bar.

This Strap is to raise the Skin to the height of the Canopy

11/06/14
 
Step 08: Cleco the aluminum sheet on the aircraft and layout  and drill #30 holes at the Roll Bar Cleco as you go.

11/10/14
 
Step 09: Layout the new Windows

11/12/14

 
Step 10: Dimple all holes, scuff and prime.  
   
Page 07.01 Lay out and cut  Aluminum
07.01 Aluminum 07.02 Plexiglass Windows  
01: Flush Rivets 02: Stab Fairings 03: Static Air / Pitot 04: Canopy Lock / Lift  05: Battery Location 06: Fuel Tanks
07: Rear Windows 08: Engine 09: Seat Adjustment 10: Seat Brace 11: Brake System 12: Electric Flaps
13: Rudder Trim 14: Tailcone Fairing 15: Wing Skin Stiffeners 16: Wing Tip Lights 17: Rear Baggage 18: Tailcone Camera
19: Tailcone Stiffeners 20: Tie Down Rings 22: Vent Door Knobs      
           
Drill Chart Tap Chart Bolt Chart Nut Chart Rivet Chart Washer Chart Rod Ends Vendors Shop Home
 

Disclaimer : Information contained on this Site may be out of date and /or inaccurate - Please Confirm any important data with a reliable source.