We made some excellent progress over Memorial weekend and achieved a milestone--the new windows are all in! I made some progress on the interior, as well, and Glenn fabricated a pair of nifty headphone terminals for the rear seats. Check it out!
(Follow up from previous post: Glenn was able to fix the fuel valve leak. It turned out to be a poorly seated gasket.)
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| The sealant, recommended by Great Lakes Aero, is Silicone II. The chemicals won't turn acidic and craze the plexi. It's also extremely easy to work with--if it goops out onto the window, just tear it away with your fingers after it dries. The windows need to be sealed well so water doesn't fall inside the skin, get trapped in the insulation and corrode the frame tubing or aluminum. |
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| The other tricks we learned when installing windows is not to make the countersink holes too deep and not to over-tighten the nuts. If the countersinks are too deep, it will dimple the aluminum. Of course over-tightening can crack the plexi--we were fortunate enough not to experience that. Our variable torque electric drill was a nice help, but hand tightening is the other option. |
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| Our plan was to keep our panel original for the time being, but we were concerned about damaging this old plastic when putting in the windshields and we'll be installing a new engine analyzer, so we decided to pull it. It's made of ABS plastic covered with a wood grain shrink wrap. Glenn likes the vintage look, but I'm inclined to have it resurfaced. We're debating. |
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| Back rest of back seat |
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| Back side |
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| The original material on the top portion of the door was an old tan tweed. We've replaced it with the felty headliner material. |
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| Ready for installation. |
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| The Fabricator at work. |
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| So what do you do with an old ash tray? |
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| Turn it into hidden headphone jacks, of course. Very cool! |
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