Window Planning

Tabitha came out to the hangar today, so I took a break from the stinky covering. We worked together to create a cardboard template for the new left rear window. We also marked and cut the left lower front door skin, which we’ll replace with something transparent. Tabitha wants bigger windows, and having windows does enhance visibility, especially while flying solo. I was concerned about weight gain, but it turns out that .060 lexan weighs less per square foot than .032 aluminum does. .032 aluminum weighs .461 pounds per square foot, while .080 polycarbonate weighs .50 pounds per square foot, and .060 polycarbonate weighs .38 pounds per square foot.

Front Door Window

Front Door Window


We also made acommodations for the front door locks.
Bearhawk Window Planning

Tabitha is working on the cardboard template for the back left window. We had to design this window before we could determine the shape of the patrol door window, so that it will all flow together properly.


Cutting out the Window Hole

Tabitha’s using the snips to cut out the window opening


Cutting out the Window Hole

Here I am doing the same. We have to take turns because our hands get tired!