Left or Right Side Windows Report No. 978/CON
Contents
1. notched and a backing support may be used This may be in the form of a backup aluminum angle cut to length or large washers AN970 6 or equivalent or a combination of large washers AN970 6 or equivalent and 1 4 aluminum tube cut to the same length as the thickness of the acrylic and used as a spacer Trim any oversized washers to clear any interior trim panels See Figure 2 8 All mounting holes in the aircraft skin must be dimpled to accept the flush mounting screws MS24693C or equivalent You may use a truss head screw AN526C 632 or equivalent to eliminate the need to dimple the skin Prime each hole with zinc chromate primer if the paint has been removed 9 Carefully place the window in position insert screws and just start the tinnerman nuts on the screws While doing this replace the trim retaining tabs in their original positions Do not tighten the screws yet 10 DO NOT USE ANY SEALANT OTHER THAN THOSE RECOMMENDED OR THEIR EQUIVALENTS THE SEALANTS MUST MEET MILITARY SPECIFICATION MIL S 8802E TYPE II CLASS B The following is a partial list of approved sealants Manufacturer Sealant Chemseal Corp Sealpak Company Inc CS 3204 B 1 2 or 2 Goal Chemical and Sealants Corp GC 408B 1 2 or 2 or 4 Products Research amp Chemical Corp PRC P S 890 B 1 2 or 2 or 4 Courtlands Aerospace PR 1440 B 1 2 or 1 or 2 or 4 Thiokol MC 236 B 1 2 or 2 The dash number on these sealants is the working time We recommend that2. necessary Start at the bottom of the window and work toward the top leaving all screws loose until all have be started then gently snug into place being careful not to over tighten 14 Smooth the sealant in each joint and peel the top layer of masking tape A pencil eraser will work well to smooth a fillet along each joint Once dried the last layer of masking tape may be removed Cut each mounting screw close to the tinnerman nut to avoid any interference with the interior trim panels Reinstall the interior trim panels glare shield and any other items which may have been removed during the installation 15 After the sealer has firmed but before it is fully cured remove the masking tape from the window and fuselage and wipe off any sealant that may be left on the window or fuselage with isopropyl alcohol and a soft cotton cloth Do not use any other solvent as it will damage the window Allow the sealant to fully cure prior to your initial flight STEP BACK AND ADMIRE YOUR WORK INSTALLATION OF REAR WINDOWS 1 Follow the Beechcraft service manual for removal of the window from the airframe 2 The windows are trimmed to fit the original opening Verify the fit in your fuselage for each window Trim and fit as necessary 3 Apply sealant as recommended by the Beechcraft service manual or you may use adhesive backed 1 1 4 x 1 16 closed cell foam sealing tape or Bostik 1100FS Urethane sealant or their equivalents Insert the window into
3. thru E55A 56TC thru A56TC 58 and 58A 58TC and 58TCA 95 thru E95 B50 thru C50 D50 thru D50E E50 thru J50 s n CD 1 thru CD 1234 s n CE 1 thru CE 289 s n CJ 1 thru CJ 25 s n D 1 thru D 9068 s n E 1 thru E 184 s n TC 1 thru TC 1298 s n TE 1 thru TE 767 s n TG 2 thru TG 83 s n TD 1 thru TD 721 s n CH 12 thru CH 360 s n DH 1 thru DH 347 s n EH 1 thru JH 176 s n CD 1235 thru CD 1304 s n CE 290 and up s n CJ 26 and up s n D 9069 and up s n E 185 and up s n EA 1 and up s n TC 1299 and up s n TE 768 and up s n TG 84 thru TG 94 s n TH 1 and up s n TK 1 and up s n CD 1 thru CD 1304 s n CE 1 thru CE 632 s n CJ 1 thru CJ 25 s n D 1 thru D 9855 except D 9819 s n E 1 thru E 830 except E 754 s n TC 1 thru TC 1935 s n TE 1 thru TE 1069 s n TG 2 thru TG 94 s n TH 1 thru TH 732 s n TK 1 thru TK 4 s n TD 1 thru TD 721 s n CH 12 thru CH 360 s n DH 1 thru DH 347 s n EH 1 thru JH 176 WINDOW APPLICATION CHART Report No 978 CON 1 28 97 Page 8 Part No WT Window Location All windows on left are applicable to Beechcraft models listed on right 294 250 92 oz Right front door window F33A s n CE 633 and up 294 375 137 oz V35B TC s n D 9819 D 9856 and up A36 s n E 754 E 831 and up 287 250WV 104 oz Right front door window assembly A36TC thru B36TC s n EA 1 and up 287 375WV 150 oz with vent installed 95 B55 and 95 B55A s n TC 1936 and up 55 and E55A s n TE 1070 and up 287 250 90 oz Right front door window wi
4. NEL CHANNEL AN97 0 6 WASHER WASHER AN960C6 AN970 6 SZ lt V SEALANT WINDOW 4 ALUMINUM WINDOW T SK SEALANT SEALANT MACHINE SCREW ACHINE SCREW MS24693C OR AN5260 632 1 SEALANTS MUSI FILL THE FASTNER HOLES COMPLETELY FOR A LEAK FREE INSTALLATION 2 LARGE WASHERS MAY NEED TRIMMED TO GIVE CLEARANCE FOR BOTH CHANNEL AND INTERIOR TRIM 3 TRIM SCREWS AFTER SEALANTS 4 AVOID OV ERTRIMMING SO THAT HAVE CURED NORMAL METHOD MAY BE USED S24693C OR AN5260 632 LP AERO PLASTICS INC JEANNETTE PA FASTNER ALTERNATIVES DRAWN BY GAM CK BY JP FIGURE 2 DATE 1 28 97 PAGE 10 SCALE NONE REPORT NO 978 CON INNER FRAME SPOT WELD es su Mf OUTER FRAME SHARPENED PUTTY KNIFE WINDOW LP AERO PLASTICS INC JEANNETTE PA WINDOW FRAME SEPERATION DRAWN BY GAM CK BY JP FIGURE 1 DATE 1 28 97 PAGE 9 SCALE NONE REPORT NO 978 CON O se se LEFT FRONT PILOT WINDOW ASSEMBLY 8 25 99 GAM DRAWING 978WV Pas le SH SCALE NONE
5. did the window Apply sealant as recommended by the Beechcraft service manual The window and frame assembly may now be reinstalled on the airframe and the installation completed using the Beechcraft recommended installation instructions in the Beechcraft service manual Remove all the masking OPTION 2 INSTALLATION amp REMOVAL INSTRUCTIONS FOR LEFT AND RIGHT FRONT SIDE WINDOWS ELIMINATING THE ORIGINAL BEECHCRAFT WINDOW FRAME 1 These windows are trimmed larger than the original windows to allow them to be fastened directly to the airframe thus eliminating the aluminum mounting frame Read and thoroughly understand all of the following instructions before proceeding with the installation 2 Follow the Beechcraft service manual for removal of the window and frame from the airframe After removing the interior window trim mark the location and mounting direction of all trim attachment tabs These tabs must be replaced exactly as removed for proper trim screw mounting tab positioning during installation of the interior trim Numbering the tabs is recommended Remove all old sealant from the inside of the skin 3 Place the new window against the upper hat section and push the window bottom past the lower hat section until it pops into position The window has been trimmed closely to fit the airframe but it may require a final trim to fit If required this can best be done by using a belt sander body grinder or band saw Both the belt sander and bo
6. dy grinder will remove the material slowly and help prevent over trimming Peel the protective covering from the window edge just enough to expose the working area and with the window in position check that the window fits flush against the outer skin If it is resting on the radius of the hat section fitting needs to be done to allow the window to clear the hat sections Mark the areas to be trimmed or radiused with a grease pencil Remove the window by pushing against the bottom of the window and trim with a disc or belt sander hand sanding block or file Again trim only enough that the window fits flush with the skin The object is to preserve enough window edge material to provide adequate minimum edge distances for the fastener holes Be sure to break all edges remove all saw marks and sand smooth using 150 grit or finer sand paper 4 With the window in position and starting at center of the sides and working alternately up and down and around drill holes in the window through the existing holes in the skin using a 1 8 AACRYLIC bit REMEMBER THAT YOU ONLY GET ONE CHANCE TO DRILL A HOLE WITHOUT CRACKING THE WINDOW USE THE CORRECT DRILL BIT These drill bits scrape a hole through the acrylic similar to a wood spade bit they do not cut As each hole is drilled insert an appropriately sized cleco fastener to maintain the window position Drill carefully using a high speed and extrmely light pressure let the drill bit do the work The obj
7. ect is to drill smooth clean holes with no edge chips Excess drill pressure may crack or chip the window as the bit breaks through the bottom side of the hole You may want to practice drilling the old window Report No 978 CON 1 28 97 Page 5 5 After all holes are drilled and the window is held securely in position with the cleco fasteners cover the edge of the window where the window meets the fuselage skin using 3 4 or wider masking tape Allow a slight gap between the masking tape and the skin to create a fillet with the sealant Also apply masking tape to the aircraft skin Apply masking paper to cover all exposed window surfaces and tape those edges This will protect the entire window surface from excess sealant as the window is installed If a double layer of masking tape is used the sealant may be smoothed with your fingers a spatula or a pencil eraser while still wet The outer layer of tape can be removed leaving a clean layer to protect your surfaces during curing 6 Remove the window and drill out all holes with a 1 4 AACRYLIC bit Chamfer both sides of all holes using a countersink or conical mounted stone Do not allow the countersink to chatter If any rough edges are produced by a chattering countersink they must be smoothed preferably with a fine stone The object is to remove all sharp or irregular edges 7 Each hole must have a minimum edge distance of 1 4 If any hole has less than the required 1 4 the hole may be
8. f AERO PLASTICS INC 1086 Bouquet Road Jeannette PA 15644 800 957 2376 Left or Right Side Windows Report No 978 CON Installation Drawing List Applicable Aircraft Models Beechcraft 35 33 thru G33 35 C33A thru F33A s n CD 1 thru CD 1304 s n CE 1 and up E33C thru F33C s n CJ 1 and up 35 thru V35B s n D 1 and up 36 thru A36 s n E 1 and up A36TC thru B36TC s n EA 1 and up B50 thru C50 s n CH 12 thru CH 360 D50 thru D50E s n DH 1 thru DH 347 E50 thru J50 s n EH 1 thru JH 176 95 55 thru 95 B55A s n TC 1 and up 95 thru E95 s n TD 2 thru TD 721 95 C55 thru E55A s n TE 1 and up 56TC thru A56TC s n TG 2 thru TG 94 58 and 58A s n TH 1 and up 58TC and 58TCA s n TK 1 and up Page Numbers 1 through 10 inclusive 1 28 97 Report No 978 CON 1 28 97 Page 2 Revision Control Page Revision Date Pages Affected Remarks Report No 978 CON 1 28 97 Page 3 OPTION 1 INSTALLATION amp REMOVAL INSTRUCTIONS FOR LEFT AND RIGHT FRAMED SIDE WINDOWS USING THE ORIGINAL BEECHCRAFT WINDOW FRAME 1 These windows are trimmed to fit inside the original window mounting frames which are then fastened to the airframe Read and thoroughly understand all of the following instructions before proceeding with the installation 2 Follow the Beechcraft service manual for removal of the window and frame from the airframe After removing the interior window trim mark the location and mounting direction of all trim attachment tabs These tabs mu
9. left are applicable to Beechcraft models listed on right 284 250 83 oz Left rear window 35 C33 thru G33 s n CD 814 thru CD 1304 285 250 83 oz Right rear window 35 C33A thru F33A s n CE 1 and up N35 thru V35B TC s n D 6562 and up 95 55 thru 95 B55A s n TC 1 and up 95 C55 thru E55A s n TE 1 and up 56TC and A56TC s n TG 2 thru TG 94 B95A thru E95 s n TD 453 thru TD 721 Part No WT Window Location All windows on left are applicable to Beechcraft models listed on right 024 250 28 oz Utility door window forward 36 thru A36 s n E 1 and up 025 250 42 oz Cargo door window aft A36TC thru B36TC s n EA 1 and up 028 250 24 oz Left 3 window 58 and 58A s n TH 1 and up 029 250 43 oz Right 44 window 58TC and 58TCA s n TK 1 and up Note All window weights are average IR eel WINDSHI LD WINDOW wa ada LACEMENT ALI NAMES len ALUMINUM ANGLE OTCHED EDGE WITH ALUMINUM SPACER Ns stash EDGE REINFORCMENT LARGE WOOD WASHER WITH WOOD WASHER NOTCHED IF NEEDED CHANNEL gs Z CHANNEL Vy NOTCH Ea WINDOW 25 e 9 MINI MUM EDGE oe 1 4 ALUMINUM TUBE SPACER V M A WINDOW WINDOW WASHER winbow AN970 6 TINNERMAN NUT TINNERMAN NUT 085950121 A 08595 012 1 SEALANT AN960C6 i ALUMINUM WASHER CHAN
10. nt pilot window assembly 211 375WV 156 oz with vent installed 978WV 131 oz Left front frameless pilot window 978 375WV 197 oz assembly with vent installed 187 16 oz Vent window use with p n 978 978WV 187 500 24 oz Vent window use with p n 978 375 978 375WV 978 146 oz Left front frameless pilot window 978 375 168 oz Part No WT Window Location All windows on left are applicable to Beechcraft models listed on right 253 250 90 oz Right front door window 253 375 134 oz 230 250WV 104 oz Right front door window assembly 230 375WV 156 oz with vent installed 230 250 86 oz Right front door window with vent 230 375 128 oz opening 980 111 oz Right front frameless door window 980 375 167 oz 979WV 113 oz Right front frameless door window 979 375WV 170 oz assembly with vent installed 189 16 oz Vent window use with p n 979 230 250 230 250WV 979WV 189 500 24 oz Vent window use with p n 979 375 230 375 230 375WV 979 375WV 979 145 oz Right front frameless door window 979 375 160 oz Note All window weights are average 35 33 thru E33 35 C33A thru E33A E33C 35 thru V35A 36 95 55 thru 95 B55A 95 C55 thru D55A 56TC 95 thru E95 B50 thru C50 D50 thru D50E E50 thru J50 F33 thru G33 F33A F33C V35B thru V35B TC A36 A36TC thru B36TC 95 B55 and 95 B55A E55 and E55A A56TC 58 and 58A 58TC and 58TCA 35 33 thru G33 35 C33A thru F33A E33C 35 thru V35B TC 36 and A36 95 55 thru 95 B55A 95 055
11. r trimming to prevent the frame from biting into the window radius cuts 6 Cleco the inner and outer frames together These holes must be carefully countersunk 100 degrees on the outside frame With the frame in final position apply masking tape to the window just to the edge of the frame and also apply masking tape to the frame This will protect both from the excess sealant If a double layer of masking tape is used the sealant may be smoothed with your fingers or a spatula while still wet and the outer layer of tape can be removed leaving a clean layer to protect your surfaces during curing 7 Place sealant Chemseal CS3204 B2 GE RTV 108 Dow Corning RTV 732 Bostik 1100 FS or equivalent in the channel of the frame The new window should now be fitted into the frame allowing the excess sealant to be squeezed onto the tape Rivet the two halves together using MS20426 A4 rivets or equivalent A layer of masking tape can be placed over the joints while fitting to prevent any oozing sealant from getting on your fingers and contaminating other surfaces This layer may then be removed to allow you to smooth the sealant around all edges leaving a good fillet Remove the top layer of masking tape with excess sealant Report No 978 CON 1 28 97 Page 4 8 Fit the window into the aircraft and cleco it into place allowing the sealant to cure Remove the masking tape and excess sealant 9 After curing remove the window Mask the airframe as you
12. st be replaced exactly as removed for proper trim screw mounting tab positioning during installation of the interior trim Numbering the tabs is recommended Remove all old sealant from the inside of the skin 3 Drill through the center of each spot weld using a 40 drill bit Mark each of these holes so that they can be flush riveted back together on the new window and will not be confused with the frame mounting rivet holes After drilling the welds may be broken with a thin sharpened putty knife struck sharply with a mallet See figure 1 Exercise care not to distort the frame Countersink the outside of the holes that were drilled through the spot welds 4 Once the inner and outer sections are separated remove all old sealer with MEK or other solvent Some sealants are polysulfide based Pro Seal PRC Chemseal etc and can best be removed using a polysulfide sealant remover such as Eldorado SR 125A manufactured by Eldorado Chemical Co San Antonio TX 1 800 531 1088 5 Fit the frame to the new window trimming the window and inner edge of the frame as necessary The window is trimmed and the edge of the inside surface is milled to fit the frame at our factory however a sander or file may be used to remove any excess acrylic The inner aluminum frame inside edge varies in size and may need to be trimmed if when fitted to the window the frame hits a portion of the acrylic which has not been milled Smooth the inside edges of the frame afte
13. th vent 58 and 58A s n TH 733 and up 287 375 133 oz window opening 58TC and 58TCA s n TK 5 and up 991 110 oz Right front frameless door window 991 375 165 oz 997WV 143 oz Right front frameless door window 997 375WV 158 oz assembly with vent installed 189 16 oz Vent window use with p n 979 287 250 287 250WV 997 997Wv 189 500 24 oz Vent window use with p n 979 375 287 375 287 375WV 997 375 997 375WV 997 92 oz Right front frameless door window 997 375 135 oz with vent opening Part No WT Window Location All windows on left are applicable to Beechcraft models listed on right 254 250 77 oz Left 2 emergency exit window E33 thru G33 s n CD 1119 thru CD 1304 255 250 77 oz Right 2 emergency exit window E33A thru F33A s n CE 180 and up F33C s n CJ 26 and up 35 thru V35B TC s n D 1 and up 36 thru A36 s n E 1 and up A36TC thru B36TC s n EA 1 and up 95 55 thru 95 B55A s n TC 1 and up 95 055 thru E55A s n TE 1 and up 56TC and A56TC s n TG 2 thru TG 94 95 thru E95 s n TD 1 thru TD 721 B50 thru C50 s n CH 12 thru CH 360 D50 thru D50E s n DH 1 thru DH 347 E50 thru J50 s n EH 1 thru JH 176 Part No WT Window Location All windows on left are applicable to Beechcraft models listed on right 140 250 82 oz Right 4 window 35 33 thru G33 s n CD 1 thru CD 1304 141 250 82 oz Right 4 window 35 C33A thru F33A s n CE 1 thru CE 315 E33C thru F33C s n CJ 1 thru CJ 51 95 thru E95 s n TD 1 thru TD 721 Part No WT Window Location All windows on
14. the 2 hour work time be used This will give you sufficient time to make any adjustments and smooth out the fillets at the joints The sealant is a two part system which requires a thorough mix prior to use It is available in both small cans which need applied by using a 1 putty knife or in cartridges which require a special hand application gun similar to a caulking gun The cartridges contain both components along with a plunger for ease of mixing and application This is a much cleaner and faster application method Remember to protect all surfaces from these sealants by covering and masking The solvents needed for clean up will probably attack the surfaces you need to clean Complete all masking Report No 978 CON 1 28 97 Page 6 11 Using a putty knife or small spatula apply mixed sealant between the window and the outer skin and hat section of the aircraft Be sure that all screw holes are completely filled with sealant as cured sealer acts as a cushion as the window expands and contracts Make sure there are no voids in the sealer that could cause water leaks 12 Tighten the screws just enough to pull the window into final position and the sealer is uniformly spread between the window and the outer skin flange Do not over tighten When cured the sealant will act as an adhesive to hold the window in position 13 Before the sealer begins to cure attach the interior trim to the mounting tabs so the tabs and screws can still be moved as
15. the frame and install the retainer moldings These retainers may or may not need repositioned slightly to accommodate the thicker window If drilling new holes position them no closer than 4 diameters from the existing holes 4 Reinstall all interior trim pieces 5 Follow the guidelines on acceptable maintenance procedures in the FAA Advisory Circular AC 43 13 1A or latest revision in completing all phases of the installation Complete 337 form The weight of the original windows in 125 thickness are one half of the weight shown for the 250 thick windows Account for the additional weight for operational performance in the weight and balance calculations Report No 978 CON 1 28 97 Page 7 WINDOW APPLICATION CHART Part No WT Window Location All windows on left are applicable to Beechcraft models listed on right 252 250 86 oz Left front pilot window 258 250 14 oz Vent window use with p n 252 250 978WV 134 oz Left front frameless pilot window 978 375WV 197 oz assembly with vent installed 187 16 oz Vent window use with p n 978 978WV 187 500 24 oz Vent window use with p n 978 375 978 375WV 978 119 oz Left front frameless pilot window 978 375 177 oz Part No WT Window Location All windows on left are applicable to Beechcraft models listed on right 211 90 oz Left front pilot window 211 375 135 oz 188 16 oz Vent window use with p n 211 188 500 24 oz Vent window use with p n 211 375 211WV 104 oz Left fro
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