Door windows attached

After the Silpruf on the rear windows had cured, we removed the clecos, and they held!

Rear window attached in place, without clecos holding it

With this, we repeated the same process for the door windows, startin with trimming the windows and sanding the door flanges (only enough for the fibers to show):

Door window flange, sanded until the fibers show

We trimmed the windows to leave a 3/32" gap, then drilled those gaps for clecos (and unlike the rear windows, on these the holes did not go all the way through, which is convenient since finishing will be easier (no repainting the inside):

Right door window held in place with clecos, after trimming

We taped up the area where we didn't want Silpruf, and attached spacers with RTV:

Left door with protective tape and spacers glued on

A first layer of Silpruf is applied to the end, then let cure for ~24h:

Applying Silpruf to the door window edges

Spreading Silpruf into a thin layer on the door window edges

Right door window with Silpruf applied, and the first tape removed

We then apply a second thin layer of Silpruf to the window, and a thick layer to the window flanges:

Applying Silpruf to the right door flange

Right door window set in place with Silpruf, held at the right depth by clecos

Left door window set in place with Silpruf, held at the right depth by clecos

We had a bit too much squeezeout on some of the inside edge, and too little on other parts, so a lot of adjusting of the inside finish had to be done:

Cleaning up the excess Silpruf that squeezed out of the inside

After removing all the Silpruf-cutting tapes, the end result was pretty good:

Right door window installed in place, after the inside edges were cleaned up and the tape removed

With this, the only part of section 45 remaining is installing the (dreaded) windshield.

Time lapse:


Total cabin door and transparency rivets: 142
Total cabin door and transparency time: 242.5h

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