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| Top view of cabin. |
Just like hatching an egg. |
Hop in back. |
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| Right door cut out. Windshield trimmed. |
Inside rear section of cabin glassed. |
1/2" recessed flange made. Yes, it looks ugly. |
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| Resulting flanges. |
Trimmed and core removed |
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Filled then 1 BID glass. |
Top with door openings. |
Outer foam removed, glass sanded. |
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| Door was glassed, then duct taped
to the door opening, BID was the smoothed out and cured.
Pockets were cut in the top of the door to receive 6 BID for
reinforcement, and to make the hinges aligned. |
Reinforcements cured, and hinge extensions traced onto fuse. |
Hinges attached to straight edge,
then attached to door. The hinges were taped, and 6-32's used to attach to
door. |
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| Top side of door. Prepped
for flox and BID over top. The hinges are permanently bonded to the
door. |
A layer of plastic was left on the BID for release. Celotex was
clamped to assist in giving the BID/flox proper shape. |
Hinge areas cleaned up and shaped. |
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| Hinges were installed and look
fine when opened. |
Here's a shot from the inside. |
Rear hinge from the inside. |
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Problem, since the hinges need to be pointed a each other, the recessed
gap is rather big. This hinge is from Velocity. |
The other big gap. These
will be redone using a different hinge. Not sure what at this point. |
On to the next door - to try a
different hinge. Here it is held in place and glassed from the
inside. |
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| Here's the door open. |
Working on the next door hinge tabs. |
Released and marked for trimming.
These will be built up on the inside like the other door. |
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| Interior of the door trimmed. |
Pockets made for next set of hinges. |
Close-up of pocket. |
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| After a lot of thought, and work-
here is the new hinge. It is self aligning which made it very easy
to install. |
The gap is acceptable, I'll
recess the screws later. |
Windows cut-outs marked. |
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Window areas masked, sanded then micro'd. These need to be
smooth in order to form the Plexiglass. |
This is the window oven.
Made of 1" Celotex, thick wire and some 1x2, foil tape and a few screws.
I had to also put cardboard over the wire. The wire left some lines
in the first window. |
Used two heat guns
and it was over 275 degrees F in about 10 minutes. Fairly even temps with
10 degrees variance. |
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| I think this will work. I
will know more after it cools and can see if the area of the window
is acceptable. |
Spread Bondo over window area and sanded smooth. |
Draped fleece and "t-shirt"
material over window blank. |
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Used the oven and draped the glass over the material. Then trimmed
it with the zip tool and carbide cutter. |
Made a pattern for the other side. |
Drilled 4 guide holes, and cut and removed outer skin.
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| Used the outer skin as a guide
and marked off a line for cutting the inner skin. |
Glass placed in opening for fitting. Looks good. |
Other side made to match. |
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Another view of window cut outs. |
Rear windows masked, and scuffed
around perimeter. |
Inner window frames, beveled foam
and taped to inner shin to outer skin. |
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| Added a foam to make a frame
around the door. Made patterns with paint mask then cut the sections
of foam. |
Shaped door frame. |
Close-up of rounded over door
frame. |
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The door was finished and frame glassed. Then cut the window to
size, masked it off, placed it in the door frame and cut the mask. |
Added some duct tape and sanded the edges. |
Final result. Windows bonded in with structural adhesive. |
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| There is a minor wave in the rear
window, but the front came out close to perfect. |
Pilot side door, inside window opening glassed. |
working on the passenger side
door handle. Removed foam for phenolic insert. |
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Bonded on phenolic and assemble Velocity door handle and supplied
lock mechanism. |
Pin tubes cut and bonded. |
Looks like a door. Filled
and glassed inside of window perimeter. |
