On 10/15/2020 10:10 AM, Jim Litchfield via KRnet wrote:
What should be used to install opera windows in the aft deck ?
Epoxy with flox ?
epoxy with micro ?
silicone based caulk ?
Please --- no speculation - I would like to hear from builders who have
done this or seen it done successfully and are happy with the results.
++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++++
Jim,
Don't make this too difficult by over thinking it. The process will
depend largely on how thick your aft deck is and it's construction.
You might want to check these photos before reading the following.
https://www.dropbox.com/s/rhrz1z31dvc4pny/PC120562.JPG?dl=0 For
purposes of this discussion, disregard the first flight grin. That was
15 years ago.
https://www.dropbox.com/s/supqavy2if9p302/PC120561.JPG?dl=0
http://myplace.frontier.com/~flesner/15.jpg (photo from inside during
construction)
For a thin pre-molded aft deck of say 1/8" or so thick, secure a
"joggle" on the inside surface using metal, plywood, fiberglass, of your
choice that extends about 3/8" in to the window opening. My aft deck had
1/2" or so foam in that area so I sanded a "joggle" from the outside and
glassed it. Cut your window to fit inside that "joggle". Mix some
resin and flox, a bit on the shinny side, and place a thin layer
completely around the "joggle": Insert the window and hold in place
till the resin cures. Clecos or small screws placed outside the glass
with the head of the screw holding down the glass or a large washer
under the screw head to hold down the glass. Whatever method works
best. I'd hesitate drilling holes in the glass for hold downs in fear
of cracking the glass. After the resin cures remove the hold downs and
fill the gaps between the glass and the "joggle" with micro mix to
eliminate any voids and even with the top surface of the window. Then
apply a 1" tape around the edge of the window and extending on to the
window to match the "joggle" on the underside. Use the very fine edge
of the tape to the inside of the window and butt up to a strip of
electrical tape applied to the window to give you a line to work to that
matches the "joggle" on the underside. Lay an additional layer of 2"
tape over the 1" tape to give a bit more overlap to the aft deck and
giving a better transition for finishing. Using the fine edge of the
tape to the inside eliminates any "finishing" needed over the glass. You
might even want to wet the tape well before applying to eliminate
getting resin on the glass beyond the edge of the tape. The electrical
tape strip will protect from there. I did all the glass on my KR this
way and not a hint of trouble in 15 years and 750 hour of flight time.
My windshield is the forward portion of a broken Pulsar canopy and the
rear windows are from left over glass from that canopy. Side windows
are from a KR half bubble. I had no plans or drawings for the area from
top longerons up. It was all built in place by "that looks about right".
I could get some more detailed photos if needed but this general
description should get you there.
Larry Flesner
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