Install Windshield
Page 45-18
Step 4: Install the C-1005 Windscreen using the same procedures as all of the other windows. (see page 45-08) but with the following cravats
-One 4 oz Weld on 10 provides an adequate quantity but no extra
- The large windscreen bonding area requires the installation be well planned and rehearsed
Step 5 Fabricate five clips from pieces of scrap .032 aluminum as shown in figure 3.
The clips are blind riveted to the F-1071 Fwd Fuselage Skin as shown in figure 2 to hold the base of the windscreen against the fwd fuse top skin. The clips are installed every 12 inches along the
lower edge of the
windscreen.
Step 6: Fabricate the windscreen base fairing as shown in Figure 1. The windscreen base fairing provides a smooth transition between the base of the C1005 windscreen and the F-1071 Fwd Fuse Top Skin. The windscreen base fairing is fabricated directly on the fuselage and consists of layups of E-glass fabric and epoxy resin as subsequently described.
Use a 7 inch radius circle gauge to determine where the edges of your finished windscreen base fairing will be placed on the pexi. Find the contact points at the from of the windscreen and bring bring it around the sides as shown in figure 1.
Define the extent of the fairing on the windscreen by placing two layers of good quality electrical tape on the wind screen. Mask Off the entire windscreen except for the perimeter areas that will be covered by the windscreen base fairing.
Step 7: Sand the exposed area with 60-80 grit sandpaper.
Step 8: Sand the area on the F-1071 Fwd Fuse Skin extending from the base of the C-1005 windscreen forward approximately 4 inches. Do this along the entire base of the windscreen
Step 9: Phosphoric acid etch the sanded areas of the Fwd Fuse Top Skin.
Page 45-19
Step1: Apply a filet of mircoballons and epoxy to fill the gap between the edge of the C-1005windscreen and the F-1071 Fwd Top Fuse Skin. See Figure 1. This is the foundation upon which strips of glass cloth will be built up to form the windscreen base fairing.
Step 2: Cut strips of 9 oz/sq-yd E-glass fabric 3 to 3 1/2 ft. long. Cut two strips of each of the widths called-out in Figure 1. Cut Parallel to the weaves.
Step 3: Lay up the strips of E-glass fabric beginning with the narrowest strips and progressing to the widest. The first layer is centered on the base of the windscreen and each successive layer is centered on the layer underneath it is shown in Figure 1.The final layer should butt to, but not overlap, the edge of the electrical tape on the C-1005 Windscreen.
Each Layer will consist of two strips to reach full length of the lower edge of the windscreen. The strips should be butted to each other with the butt joint of each layer located one to two inches away from the butt joint of the previous layer.
Step 4: When the lay-up is fully cured, the surface may be shaped and sanded smooth.
Use a sanding block with the same 7 inch radius as the final lay-up. Begin with 40 to 50 grit sandpaper to get the general shape Use caution so as to not sand the electrical tape on the C-1005 Windscreen.
