Side "D" Shaped Windows

March 20, 2011

The fixed windows run from the aft end of the main cabin door opening all the way back to the baggage compartment behind the rear seat.  They are shown in detail on drawing 17 and are made from 5052 aluminum.  To make things easy on myself, I ordered the side window frames from Avipro.  

The bottom of the window attaches to the top side stringer and the aft main cabin door opening former.

I started by positioning the side window frame aligning the bottom edge of it with the stringer and clamped it in place:
 

I split the window frame and slid it over the door former with one side of the window frame on each side of the former.

This will leave me a way to slip the plexiglass in later.  I will also make a piece of angle to go over this opening and be screwed to the door opening former.

Here is what it looks like from the inside with the window frame clamped to the former:

The bottom of the window frame is stabilized by the stringer but the top side is just kind of hanging there and needs something to stabilize it as well.

I used 3/4" x 3/4" square aluminum tube that is 1/16" thick.  This was purchased from the airplane parts section of the local hardware store.

The square tube is the same width as the surrounding tubes on fuselage so fabric covering should be a nice smooth transition.

The mounting brackets for the 3/4"square tube were made the same as the stringer clips only larger. They were positioned and welded to the vertical tubes and the diagonal tube at the aft end:

Here is the square tubes from inside the cockpit:

The side window frame was drilled to the stringer at it's bottom and to the square aluminum tube at it's top. Here it is drilled and clecoed in place::

Here it is from the inside:

This system makes a very rigid, yet light-weight installation for the rear side windows.   I will later make a cover piece for the forward end of the window channel where the plexiglass slides in.  This removable cover piece will be attached to the main cabin door opening former with screws.

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