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As our Aztec was down due to a leaky prop seal, we began the install of our
new 1/4" side windows. After removing the plastic surround trim and mapping the screws, because they were several different sizes and lengths, we then had to remove the window retainers. The retainers are basically some fancy L shaped aluminum pieces that when installed hold outward pressure on the windows forcing them into the adhesive tape that Piper so liberally applied when the plane was built. Our old windows were a thermo pane design consisting of a 1/8" outer window, then a space created by the retaining bracket, and a thinner inner pane of Plexiglas finishing up the sandwich. I'm sure that Piper had good intentions, but this design leaves no ability for cleaning the insides of either the two panes. It also allows the panes to rub together and chafe, creating a lot of crazing. So after removing the window retainers, it was time to do some serious cleaning. The adhesive is a fabric tape coated with 1/4" of a black tar like substance that is nearly impenetrable with any kind of solvent. MEK seemed to work a little, but most of the time it just made it smear. The best method that we found was after scraping as much off with plastic putty knives, we would create a small ball of the goo and then use it to dab onto the window sill then briskly remove it so more black goo stuck to what you held in your hand. Kind of like dabbing chewing gum off your kids face after they blow a bubble. A second round of MEK cleaned things up very nicely. Most of the LP Aero windows fit right in, but the pilot's side window and the cabin door window required roughly 1/4" be removed from two sides. A fine toothed band saw blade worked well followed by finishing and beveling with a belt sander with an 80 grit belt. LP was nice enough to notch out the top of our passenger side center window due to the protruding rivets along the top, but for some reason they forgot that the pilots side window has the same rivets. Oh, well the bandsaw and the belt sander made quick work of resolving that problem. After dry fitting with the protective plastic still applied to the windows we pealed the plastic off and then squeezed a nice thick bead of black silicone to both the window frame and to the window itself. Being super careful not to touch anything with the pre-gooed window, we slipped them into position and then pressed them tight, forming a good seal letting the excess silicone ooze out from around the edges. After mistakenly letting the first two windows set overnight, we quickly learned that it is easier to clean up the messy wet silicone immediately after installing rather than letting it dry then cutting and scraping it off later. With fingertips blistered from rubbing, lesson learned, not to be forgotten. Reinstalling the retaining brackets was a no brainer. While the silicone is still soft, fit into place, press against the window until the screw holes line up, reinsert screws. No need to drill new holes for the thicker windows, they simply took up the same thickness as the old thermo pane design, but since Piper never installed 1/4" windows in the Aztec we couldn't get away with the part 43 logbook sign off for simply "replacing side windows". LP required a 337 for this install and notices about it were plastered all over the packaging. Since we ordered them through our A&P - Aztec owner friend, he filled this out and it was approved through the mail and with a phone call as "previously installed under previous documentation and approval in same make/model". So with windows in and approved, now it's just a matter of refreshing the condition of our 40 year old plastic trim. Plane Plastics demands roughly $135 for each of the 5 pieces that surround the windows, so before spending that kind of $$$ we decided to see what we could do with a fiberglass repair kit and some spray paint. After searching the group posts and reading up on what people were using to paint plastic and what SEM paint cost, I talked with a couple A&Ps that work on many of the rental planes in the area. Their paint of choice? Fleet Farm. (a local midwest farm and home supply store) Good coverage, no pealing, no sticky residue and their Almond color matches the old Cherokee off white, and the Sand pebble color matches the old Cherokee tan color. After sanding, prepping, patching, and reinforcing the screw holes with fiberglass, a little sanding then cleaning with MEK, the first piece was ready for the paint test. I must say that the cheap FF brand paint worked as advertised. I gave it 3 light coats then let it dry overnight. Once installed, the first piece looks as if it had just came out of the factory... well almost, but a lot better than the hole $135 would have left in my wallet. Two more pieces ready to go in tonight, then just 2 more to go. For those who have repeatedly contemplated how great their plane would look with new glass but have had a fear of the costs, this is a project that you really can take on yourself and do a nice job with. Total cost for us for tinted 1/4" side windows will be less than $900. (note: we did not replace the emergency exit center left window as it is a single piece design, rather hard to replace, and was in excellent condition) In most cases, if your side windows are an exact replacement, no A&P or 337 is required, just a simple pilot sign off as part 43. The first thing that we noticed was how the new glass made our paint job look even better. I can hardly wait to see how they look from the inside from the air! More info he http://www.glapinc.com http://www.lpaero.com/ Jim Burns |
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