Windows and Windshield

I have finished the main work on the windows and door and have the intial fit on the windshield done. On the rear window frames I decided to use 3/4 in square tubing so I would have a surface to attach interior panels too later. We also decided to put a window in the main door to help with visibility for floats and for better views. A bit more work for sure but worth it. I went with 2.5mm plexi for all the glass. Any thicker than this and the rear windows would have been too tight a fit and I thought it would be a good thickness for main windows as well. All the trim pieces around the windows and door is .025.  The skylight will be 1/8 bronze lexan.  How I did the windows is shown mostly on the door. I used 1/2 x 1/2 x .062 aluminum angle but machined one side down to 3/8 so that part would sit down nicely against the tubing and not leave a ridge.

I only took  pics when the windows and door were finished and ready for riveting but I will try and show how I did them.

We decided that we are going to bond the windshield in place as this will be a much nicer finished look in the end. I also remade the side formers too allow a larger area for the windshield to slide behind.

New side formers.

Windshield set in place and trimmed. It will be one of the last parts to be permanently installed.

This will be covered by the fabric and a thin piece of trim.

Lower detail window closed.

Rear window frame joggle, this is needed as rear window sits proud of door frame.

Still have to put window latch in and will be putting small gas strut in as well to hold window open.

I drilled a hole thru the tube that the latch slides in so grease can be inserted during annuals. That is what the cover is hiding.

Riveting all done. That’s Brian hiding behind windows.

There will be a clip for latch to lock into when closed.

Next few pics show how I closed in the latch.

Door all ready for final riveting.

You can buy drill bits for drilling plexi but it’s easy to grind them. We call this”spading” the drill bit in the trade. You just grind a flat across the cutting flute so your taking away the rake to stop it from grabbing the plastic when drilling thru. The same thing is done when drilling thru copper and brass.

I drilled out the holes in windows to 5/32, this allows room for any expansion but more importantly helps keep stress away when riveting.

I drilled thru with a # 40 first, then took apart and drilled out angles to #30.

Outside trim drilled and clecoed on and inner frames ready for drilling.

Drilling all the frames.

Machining down one side of angle, couldn’t find any 1/2 x 3/8.

All the pieces laid out and primed ready for assembly.

Window was installed and I marked a line around inside of frame. Then I measured out 5/8 from line and cut window. This allowed for some up and down play to aid in fitting window. Pic shows window after cutting.

Trimming detail.

Top forward section of rear window trim detail.

Bottom forward section of rear window trim detail.

Opening to allow window to slide in. This will be covered by trim later.

3/4 in tubing used instead of angle so I can attach side panels easier.