Silverwing AEROPRAKT A22 FOXBAT, Manual

Page: 165 / 185

Page 166 - © SilverWing Aviation, 2005
PAGE FIFTY-NINE
DRAWING NUMBER 1.390
Fitting the Windscreen
Recommended job for three persons; one at each side and one to position
the lower edge.
Note. This is a tricky process to complete accurately so
each person should be familiar with the method and their own part in it.
You will need something secure to stand on at each side of the fuselage.
One person to be Leader. Don’t rush it!
Locate the pre-cut Lexan windscreen and de-burr the edges using the same method as for
the aft glazing. Peel back the protective film about 50mm inside and out. Using a straight-
edge very accurately mark a chinagraph line vertically down the exact centre of the
windscreen on the outside. Locate and inspect the pre-drilled side angled Dural strips and
the curved pre-drilled Dural trimstrip (not illustrated) for the lower side-to-side
attachment. Offer up the windscreen by butting the top edge into its slot snug against the
corrugated roof panel and
underneath the wing fillets. The upper transverse support lip is
also pre-drilled so, first making sure the screen is exactly central, one of the side assistants
must drill and clico the top edge. Next, with the lower assistant supporting the windscreen
and keeping it exactly central the side assistants should press the Lexan into a curve snugly
following the inside contour of the wing fillets, then drill and clico the Lexan to the curve.
Warning. Don’t lean on the wing fillets at this point or they will be “set” inwards possibly
resulting in an unequal and unsightly gap at the wing leading edge/fillet junction.
Now go to the lower windscreen centre and, working outwards equally towards either side,
clico and drill to form a Lexan “sandwich” between the Dural trimstrips and the fuselage.
If during this process the windscreen “overlaps” its lip in the bulkhead then
very carefully
“un-clico” and shave it to fit with a Multi-file. Now take the Dural strips and fit them tight
against the fuselage side tubes thereby sandwiching the Lexan again. Using the Multi-file if
necessary make sure the Dural is snug against the tube’s side and rear 90 degree points and
are also flush with the sides of the fuselage, then drill and clico in place.
Thoroughly examine the work so far for a good fit. “Straight-edge” the wing fillets or offer
up the wings if you feel that the fillets may have taken a “set”.
Finally, replace the clicos with pop rivets by working carefully outwards or in an
appropriate sequence to avoid “pie-crusting” the edges of the Lexan.