Disassembly of large D window

[Mark Julicher]

I know this topic has come up before, but since this is the first time I have taken one of these apart I thought I would share the fun.

The inside and outside aluminum flanges have been discussed at great length before. The rubber channel here is ancient and will be replaced. The plywood baggage area is 1/16 thickness and tucks up under the inside aluminum flange.

The fabric goes over the aluminum flange and is pretty much clamped in place.

The plexiglass replacement needs to be tinted - way cool?

[Mark Julicher]

Re: Disassembly of large D window

Dry rotted wood is everywhere in this plane. I'll have to inspect those spars for real! These machine screws and Tinnerman nuts are rusted beyond recovery too.

[mulwyk]

Re: Disassembly of large D window

Thanks for posting the pictures, Mark. Very interesting.

All that rust and wood rot! She's been wet alright, for years maybe. I'm sure you're a little nervous about what you might find when you open her up. Do you think the windows were leaking?

[Mark Julicher]

Re: Disassembly of large D window

I'm sure the windows were leaking as well as 100 other places. Looks like all the wood in the fuselage will need to be replaced.

[Pearson]

Re: Disassembly of large D window

Mark,

Thanks for posting those excellent pictures. It appears that, other than the rubber gasket, there was nothing between the glass and the lip of the outer frame. I suspect that the gasket got hard with age and allowed moisture in. I am surprised that they used plywood as a support for the window frames.

As you may have seen from some of my posts, I fabricated some frames to use on my project. I plan to use the stuff they install car windshields with as a sealant. It comes in a caulking tube and is VERY sticky. Also, it never hardens. It stays elastic with age, so I am hoping to avoid all the moisture damage seen in your pictures.

Thanks again!

[Mark Julicher]

Re: Disassembly of large D window

Richard,
Yes, I studied your D windows with great interest and that is what prompted me to put these photos out there.
I have a lot of wood work to do, so sealing the windows is a good idea.

[Hank Jarrett]

Re: Disassembly of large D window

When I swept up what looked like potato chips from the bilges of my plane and realized my windows were held in by the screws through the fabric I decided to seal all of the wood like it was primary structure. A careful coat of Poly U varnish is on all surfaces of my new wood parts and they could survive long term submersion in a polluted river. I even put it all together then took it apart again to seal all of the screw holes. NO water is getting in there!
They better still look like new when I recover.
Hank