I'm grateful that the FAA considers installation of the door windows to be eligible for pilot/owner maintenance under Part 43 (based on my extensive research and conversations). Still, it is a bit surprising just based on how the FAA works in pretty much every other area.
4TV was moved back out onto the ramp yesterday while it awaits the left mag to return from its overhaul. With the work likely not to be done until next week, and with the family and I traveling for the holiday then, I wanted to go up to the airport to drop the tailBeacon off with the avionics shop on the field anyways, so it seemed like a good opportunity to try and get one of the windows done.
My son and I pulled my car up between my airplane the one one next to it to get started. The co-pilot side widow is the worst - with heavy glazing and some type of white substance in areas that makes visibility challenging, so I figured I'd knock that one out before the pilot side.
Surprisingly, the co-pilot side door was super easy to pull off. It consisted of two pins running down the hinge that were easily slid out. Easy-peasy and my son and I took it to the back of my truck to start the work of removing the frame.
Removing the rivets was not as easy as the videos I watched made it out to be. First off, the rivet side that I had going up into the hinge that connected the frame to the door was not the end with the rivet going through the ring, but rather the flat end. Careful drilling and some chipping away finally got rid of them, and I was able to pop the window off.
I was going to try to do the pilot side window as well, but discovered that the hinge attachments on that side were screwed in. The second screw I tried to release was stuck on too good for my small screwdriver - so not wanting to risk stripping it, I figured I'd come back with a larger one later. I taped up a plastic bag around the exposed co-pilot side window and headed home.
Two additional things were more difficult than I anticipated. Once I had the rivets out of the area that connects the two ends of the frame together, I discovered that separating the parts wasn't easy. I also discovered that I removed three rivets I didn't need to, but that's not a big deal. Eventually I slipped a flathead screw driver into the seem and worked it enough to get some separation that eventually allowed me to use my foot to pull the two sides apart.
Second - removing the window itself was difficult. It didn't want to come out easily, even with soapy water, so I found I had to break it and pull on the pieces. this probably took 30-minutes, and the old u-channel didn't want to come out easily either. Eventually it all did, butt this took some time. I cleaned out out the channel and stared at the bare aluminum frame, realizing that I should probably paint it - if just to look better. A quick run to Home Depot for some spray primer/paint in winter gray (close enough to the cabin panels), followed by painting, and then off to bed to let it dry.
Side note - when dumping all the loose parts from the frame, two springs popped out. I suppose that someone dropped a spring in the frame when trying to install it previously, which made me laugh. Both were heavily rusted.
The next morning I decided to give setting the window a shot. I hard ordered a u channel from the manufacturer and carefully worked it around the window, which I had prepped by pulling back some of the protective layer around the edges. Point of annoyance - the logbook sticker for the window was attached to this - so apparently I have to cut it out to apply to my logbook.
While the channel went on fairly easily, my efforts to get it in the frame met with failure. I had applied extensive soapy water on all parts, per the video I watched. The problem is, that same soapy water made the u-channel slip from the window. I didn't get very far before realizing it wasn't going to work, and that I needed to go to my day job.
Stopping the project for now while I wait for vulcanized rubber tape to be delivered. This is what was recommended on the YouTube video that's out there, and I can now see why. With that tape adhering to the window, it should make it easier to get the window in the frame. More to come in Part Two.
No comments:
Post a Comment