Windows - Part III: The big one...

As the title says, onto the big one.

I've had it home for a couple days and have been looking at it, moving it around, and thinking a lot.

My first realization is the window was not fitting in the top joggle, which is bringing the window up and the front.  Lots of overhang on the pilots side, but little to none on the copilot side.

So I called the master for advice.  Bottom line, there is no one size all solution... you have to look at what you have and what you want to achieve.  My first thought was get the top joggle to fit, but Zach said not necessarily.  I know I need to bring the window to starboard, so work the top joggle on that side first.  Then start the front to get it to fit.

The window keeps wanting to slide forward.  So I am going to make some blocks that can be clamped on to hold the front in place temporarily.

I finally decided to jump in and start trimming.  I trimmed the edges on the top joggle to get the window to fit.  Trimmed more on the copilot side as that is where I had less overlap on the lower side of the window.

It must have been 12 iterations of on/off/on/off.  I really dont want to have to buy a new window.

So now I am trying to get the front to JUST fit into the joggle.

It was at least 20 trim cycles to get it in.  Once I had the top fitting, i focused on the center of the lower edge and then worked my way out.  The goal was just enough gap that I could get a cleco in.  Next is the sides, and then finally I can start working on a consistent 3/16 gap all around.

After consulting (again) with Zach, the process on the front window differs from all the other windows.

• Place silpruf standoffs every 6".
• Place clecos where you need them to get the window to sit right.

So after many more trim cycles, I have the window now in the joggle all the way around.

I need top open up the top seam on the top deck enough to get clecos in, and I need to refine some of the standoffs a hair.

The problem with this window fitting from a high level is if you chance something in one area, everything else moves around a bit.  I took the slow and steady approach.

OK - fast forward almost 2 years (from December 2023 to August 2025.  Fuselage is painted, and the window is going in!

I was working on removing any small scratches, and used a polisher WAY TO FAST and crazed the hell out of a corner of the front window.  I wanted to cry... all that work and time, and I just destroyed by window.  BUT... a fellow builder at the airport trundles around the corner of the hangar building to see the progress... and I am just devastated.  "No problem" he says... "I have what you need".  He returned with 800, 1000, 1500 and 2000 grit sandpaper, and I spent the next day and a half getting the crazing out.

I had also somehow put a good ding in the middle of the outside of the window.  That is now gone too.

Then I got back to prepping the window to go in.  Standard front window progress.  Mark the goggle on the outside, 1/4" tape offset from the line, then the 2 fine line tapes, sand with 200 grit, apply the 'beautification layer', let sit for 12 to 24 hours.  Had problems with the fine line tape in the corners by the wing root.

And the window went in today (August 28).

Now the 7 day wait begins.... fingers crossed.