Posted by john wilkinson
on 19/7/2008, 11:11 pm, in reply to "Re: building a Lysander"
89.242.241.100
I am not amember of your Assoc but many years ago I built a Lysnder and had to face the problem of window fitting.
I cut the perspex panels to fit the holes exactly, then made two oversized 'frames' which overlapped the perspex by about 3/4 inch inside and a similar amount outside.
This allowed the perspex to be trapped between two plywood panels. These were drilled through the outsides so that the holes pierced three thicknesses of wood. The whole was filled with a commercial sealant (silicone?) and the whole bolted together using the plastic nuts and bolts associated with motor car number plates.
Provided you use care in finishing the edges of the frames and the squeezed sealant carefully removed, a neat and serviceable job results.
The plastic bolts will give when the cabin flexes and it is not possible to crack the perspex because the bolt will shear first.
This solution lasted for years after I parted with the vessel.
Hope it helps.
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