Drefs.net

Well I thought I learned enough with the first window to make the second one much easier, and it was easier, but it had some new issues to deal with that made it challenging.  It went better, but despite our best efforts still had quite a bit of smudging in places we didn’t want glue, and a spot that came out too high for some reason.  On the plus side, the joint bonding looks real good, so structurally it looks fine.  As with the first window, the clean-up effort will determine how I proceed.  I ordered the special tools to scrape the windows clean, hopefully, so we will see how it will go.  Too tired to do anything tonight, so vegging on the couch, but tomorrow will finish the defrost fans and some other smaller tasks.  Lots of small things left.

Total project time: 1517 man-hours

Saved by Nair hair remover?

The last couple days I got some time to work on the airplane.

I started out putting in new overhead switches, ones that would light up even if they were in the “off” position.  The other ones I had purchased were either too bright (so I was worried about glare at night), or were not lighting up with power on, so you couldn’t see them at night unless the switch was turned “on.”  I did not realize some switches were different, so I had to order from a different place.  I like how the new ones came out, and the switch was pretty quick and easy.

Then I started working the defrost fans, which had come with the new switches.  Had to drill lots of holes to make a “grill” opening for the airflow.  Here’s how it looks before mounting the fans and doubler skins.  Lots of holes!  Should do the job.  Still have to rivet in the doubler and mount the fans, then run a few wires.  but first…

I decided to start on the rear windows, since the special adhesive has a time limit for storage and mine was getting old.  I was pretty nervous about this step, but thought it would be straightforward.  What a stressful step this was!

I thought I was well prepared, but no.  I under-estimated how much the gooey glue would run and then get all over everything.  I had masked off the window, but not well enough.  And then it started dripping and getting all over the interior and exterior, which I had not thought I would need to mask off.  And the glue is setting up quickly while trying to get that mess dealt with.  On top of that, it is critical to get glue along the entire joint all the way around, which is not easy in itself.

Normally you could just wipe down the excess spillage with a strong solvent, but in this case, the plexiglass windows are chemically sensitive.  You cannot get any strong solvents anywhere nearby as even the fumes can cause damage.  Even something as mild as alcohol cannot be used.  Glue got everywhere.  So I was pretty stressed.  In 15 minutes the glue was pretty well set and we could not get it off my poor plexiglass window, nor my already-painted interior.  Just wiping the glue didn’t work, as it is thick and sticky by the time you get to it, so it would just smear all over.  Tricky stuff.

Now, I did manage to mask off enough of the window that I could make it work, I think, by putting a layer of fiberglass around the edge as many builders do to improve the look, and the spillage on the interior and exterior can be sanded off and repainted, it will just take some work.  All this assumes the window itself has not been damaged in my efforts.  But it is not my first choice of approach.  So…

After a bit of panicky research, and running around like a chicken with it’s head cut off, I decided to try the mild solvent recommended online, and some manual labor.  The plexiglass is glossy which makes it challenging for adhesives to stick, so I thought it might just scratch off like paint on a glossy surface in the areas I had not sanded in preparation for this.  I was worried about scratching the window though, as plexiglass is very soft and easily scratched- even wiping dust off of it can cause fine scratches.  But, I hoped using a plastic scraper with the mild solvent might do it.  Just to be sure, I stayed only in the boundary area where I might eventually have to just cover it up anyhow.  I needed a stiff plastic scraper, but the only thing we came up with is a Nair scraper- the thing women use when shaving their legs with that chemical hair remover.  It actually did a nice job for a test run, and didn’t seem to cause scratches although you can’t really tell without a strong light which I didn’t have handy.  I will check again tomorrow.

Anyway, it took a lot of scrubbing, but it did seem to work.  So I have decided to buy some special sprapers for the job, including one or two made to be put in a rivet gun- power tools for the job, yeah!  I am glad I only attempted the one window.  As with many things on this project, the first attempt is rough and you learn how to do it right the second time.  Still three more windows to do, one rear and later the two doors.  Worst case now, assuming no chemical damage to the current window, is one kid will have a slightly smaller view out the window than the other (it will hardly be noticeable, really).

More tomorrow night.