Title: Aluminum formers, stringers, window frames
Many entries consolidated here. Several months of part time fiddling, research and fitting to get the exterior levels of the plane established to accept fabric. Instructions would have saved many, many hours here. All the aluminum stringers bent and attached. Many had to be notched or raised above the tube work in order to accomplish the shape I wanted. I started with 3/16 rivets, but Dan York strongly suggested steel screws. I went with two #6 screws through the steel clip and both sides of the stringer in each location unles I wasn't able to get a screwdriver on. In those cases I used rivets and in one case, a machine bolt with a nut. Screws were cut to length and secured with blue locative. Aluminum formers permanently riveted in place. I'm a little concerned about the 1/8” slot between the rear window frames (where the window pane sits) being uneven in width and too tight in places to accept 3mm acrylic as well as a layer of fabric. I read somewhere that they could be pried and stretched apart as required, and Mark G verified this. A better way to go would have been to drill out the rivets holding the inner and outer window frames, attach the outer frame, cover, then rivet the inner frame back onto the outer with the window pane sandwiched in between. I will try prying the frames apart carefully with a large chisel or some other blade. I could also switch to 2.5 mm acrylic panes (probably will) and I could grind a chamfer on the outer edges of the acrylic pane with a grinder to ease the fit. Might have to do all three. Placement of sealant promises to be messy. Masking required.


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