Windows

The quarter glass was the easiest. You'll need the glass and the foam adhesive-back tape that goes around the edge. Each quarter piece is held in with aluminum brackets, secured with a couple dozen (#1?) screws. I did it solo, and I estimate I put in 4 hours total (after the trim was removed, which takes a few minutes more...)

The canopy was a bit tougher, but not impossible. Look over the article that just appeared in the Star regarding re-doing the interior trim; THIS is the part that takes the longest time, because you have to drill out and rivit the plastic pieces. If you're planning on re-doing the canopy glass, it would also be the perfect time to refinish or replace the canopy plastic trim. Beware: replacing the canopy trim will take the lion's share of the the time.

Let's say you have the canopy interior trim removed and the canopy is sitting on your bench. Removing and installing the glass is a good two-person job, just because working with the canopy solo is awkward (but not impossible; I spent my Christmas Day afternoon wrestling a Grumman canopy...) You remove two rails at the "bottom" of the glass that secures it (these rails are held on with about 8 bolts/nuts) and you slide the glass "down" and out. Installation is the reverse; you'll want to wrap the edges with the same sealing tape you used on the rear quarters, and you'll want to soak the edges real good with Windex before you attempt to slide the glass back in (the Windex provides lubrication, which evaporates later). Making sure you work in a warm area makes the glass a bit more flexible, which is necessary to get it to fit in. After that, replace the lower rail, re-install the plastic trim, and re-install the canopy onto the airframe.

All told, I spent about 20-25 hours doing the canopy: replacing (and trimming, and trimming, and trimming) the plastic, replacing the glass, and re-installing the canopy. their 25-30 hour estimate is not out of line if it includes all that.

Then again, you could just do it yourself. Plan to have the airplane in a hanger, covered, while the canopy is off.

I replaced my canopy and rear side glass last year. The canopy must be removed to replace the glass. The difficulty with canopy glass is that it must be pushed up into the channels. The window is curved on the top and flat towards the bottom which causes you to force the curved part flat before it slides all the way into place. I had one side given to me when I purchased the plane. It was probably at least 3 years old. It cracked about 2 inches as I was putting it in. I don't now if it was because it its age or maybe it was too cool. I used a hair dryer to warm up the other side and it went in OK. Keeping the felt or foam tape in place is difficult.

The rear side windows are easier as all sides of the retaining channels are removable. I used clear silicone to seal the outside edges in addition to felt to seal the edges. I would estimate 2-3 hours per window.

I have never done a windshield but I understand triming and fitting is time consuming. You wii also need 10-16 clamps for securment to the bow while the sealant dries.

the canopy side windows were a bear but the windscreen was even more of a problem.The one we got came oversized but was marked where to cut it, which worked out allright but did take 4 or 5 hours just to prepare it to be installed and then a great deal of care had to be taken to make sure the canopy seal fit just right.Even as careful as we were(and my AP was an experienced Grumman shop) We got a small stress crack which lucky for us it was in an area we could put the Temp. gage probe.

I've done the grunt work of replacing the side windows a couple of times. There's a real temptation to muscle the pieces into place...and once a window cracked while I was encouraging it to sit where it should. TEMPERATURE, TEMPERATURE, TEMPERATURE is the key....warm plastic is a whole lot more forgiving. And new panels seem much less brittle than "seasoned" ones.

it took three of us (NONE with windshield replacement experience) about 9 hours (or 27 manhours) to remove the original 1/8 in. thick windshield and replace it with a gray tint 1/4 inch windshield.

At the AYA Convention this past July, Ken Blackman had some video of a windwhield replacement. One of the key points was the use of 90 degree angle brackets between the leading edge of the canopy face and the windwhield bow to keep the two parallel during the installation process.

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