Posted for "Justin Hawkins" <JustinH@lancair.com>:

 
 
      2244 Airport Way Redmond, OR 97756
 
          (541) 923-2677 (541) 923-2255 fax
 
                 lancair@lancair-kits.com
 
 
 
 
 
 R&R Cabin Door Window
 
 
 
 1. Remove the forward and aft latches that are on the window.
 
 
 
 2. Remove enough of the inboard cabin door stiffener to get access
 to the cabin window.
 
 
 
 3. Remove all bids around inside of cabin window.
 
 
 
 4. Sand or Grind the remaining window pieces away. Making sure not
 
 to grind or sand into the outboard door skin. A sharp chisel may be
 useful, but be very careful not
 
 to penetrate the outboard door skin!
 
 
 
 5. Trim the new window to fit in the cabin door joggle.
 
 
 
 6. With the cabin door window fit in place, drill the two (2)
 forward 3/16" holes and the two (2) aft 3/16" holes through the cabin
 door window using the latches as the drill guide.
 
 
 
 7. Remove the window and drill out the four (4) 3/16" holes to
 5/16"- 3/8".   See figure 01
 
 
 
 8. Install the new trimmed and drilled cabin window per the Lancair
 Manual. Making sure that the 3/16" holes in the latches stay centered on
 the 5/16" - 3/8" holes in the window, and that no hysol fills the holes.
 
 
 
 9. After the window has cured. Re-apply a 4 Bid lay-up around the
 window as per the Lancair Manual.
 
 
 
 10. Redrill the four (4) 3/16" holes through the 4 bid lay-up.
 
 
 
 11. Re-Install the latches with the new hardware. When installing
 the new MS24694 screws, use tinnerman washers (A3235-028-935) the head
 of the screws. Fill the 5/16" - 3/8" holes in the cabin window with RTV
 silicone prior to installing the screws for the final time.  See figure
 02
 
 
 
 12. Replace the door stiffener that was removed in step 2 with 4 -
 6 bid of Carbon Fiber.
 
 
 
 
 
 
 
 Justin Hawkins
 
 Lancair Airframe & Technical Support
 
 Lancair Int. Inc.
 
 250 SE Timber AVE
 
 Redmond, OR 97756
 
 justinh@lancair.com
 
 541-923-2244 ext 121