DESCRIPTION

The Window Liners are the window frames (window frames) that one can find at the different raamframes.

They're ready to buy from some company that cockpit stuff to sell. Generally they are very pricey and they should also just fit with the window frame that one uses.

It is also the intention of the ‘Window Liners’ to make one yourself.

The Window Liners are divided into :

  • Middle strut windshield window liner;
  • Side window armrest/Chart holder (Capt and F/O);
  • AFT Lower window liners (Capt and F/O);
  • AFT Upper/Middle window liners (Capt and F/O);
  • FWD Upper/Front window liners (Capt and F/O);
  • Imitation glass (plexi or pvc).

 

FWD UPPER WINDOW LINER

The ‘FWD Upper Window Liner(s) are located at the top of the first window opening. Like the other liners, these liners are also made out of styrofoam.

Not the gross white styrofoam that we know of packaging, and styrofoam with a high density and very fine grain. This styrofoam can be found under the name Styrodur (blue or green) or PolyFoam (grey). This piepschuimpanelen be used as insulation material.
This product has the property of being very solid and well machinable (grinding in a correct form).
For the "window liners" have I PolyFoampanelen use of 50 mm thick.

The various sides (top, bottom, and outside edge) of the 2 upper liners’ are in the correct angle cut, and this in accordance with the various interior angles of the aluminum frameomlijstingen. Corners first can be determined by use of a protractor.

 

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As with the other ‘window liners are the inner sides 50 mm wide and the voorzijdes where one face looks 40 mm wide.

First I have a full length of the upper window liner’ (corner to corner), then I have a little piece of them that corresponds with the shape of the corner between the first side window and windshield (so diagonally down).
That piece I have on the front, at the bottom of the upper window liner’ glued.
When you have the real ‘window liner’ view, there is also bend in the corner that a piece of to under.

Fwd Upper Liner1

 

When the ‘window frame’ with the plexiglas with bolts to the ‘window liners’ also be provided with the necessary holes for the bolt heads to them to begin.

 

FINISH OF THE FWD UPPER WINDOW LINER

The intention is, first, the styrofoam extra sanding until the shape is the correct surfaces and curves. This, of course, that as much as possible corresponds to the real instance. It is a bit like sculpting ... 🙂

After the styrofoam to be consolidated to a hard and sturdy surface and prepared for painting.

Acrylic One
In a previous process, for strengthening of the styrofoam, which I middenstrut of the windhield’ have finished, I have epoxy resin used, and this together with glass cloth and shipping to most european countries.
The epoxy resin I have now been replaced by’ Acrylic One‘. I have found that the use of epoxy resin is cumbersome and not particularly healthy to breathe in.
The idea is to opt for "Acrylic One" comes from a fellow cockpitbouwer Dion (Prosim nickname: Dion73).

Acrylic One‘ it is a mixture of powder and liquid with a slurry, obtain one with a soft brush can smooth, for example, polystyrene. After a drying time of 1Hr is the coatings hard and ready for sanding. You can compare it with plaster, but much harder. Acrylic One is easy to use and is particularly odorless.

To try I have a test kit purchased at Poly-Service (EN). All about Acrylic One is comprehensively explained on their website:
http://www.acrylicone.nl/
http://www.acrylicone.nl/Education/Youtube

In this test kit, I also got a bottle of Acrylic One Thix A bought. This liquid can be extra to the mixture do to the slurry to thicken so that the mixture becomes thicker and less liquid. Good for large grooves or holes to fill.

Now, what is the procedure?
After the mixing, (1 min) of the correct proportions (1 gewichtsmaat liquid LPO1 Liquid and 2 gewichtsmaten powder LPO1 Powder) the mixture is ready for use. This mixture is +- 20 min useful.

  • A layer of Acrylic One mixture to the styrofoam with the supplied soft brush;
  • When this layer is still wet then add a layer of glass cloth over it (it is recommended that the glass cloth in advance cut to size – time-saving!);
    Note. In the test kit, there is also glass cloth but which is much too coarse to use. Glass cloth with a finer structure is easier and better to work.
  • After the application of the glass cloth is again a layer of Acrylic One over it applied.
    All actions happen in succession without waiting for curing.

To the firmness additional to improve, one can possibly these 3 repeat the process. For the ‘window liners’ is sufficient to do this but once.
After 1Hr all would be cured, but I for safety, waiting until the next day.

A bit more explanation about the different procedures are to be found on the following page: https://www.flightdeck737.be/hardware/platform/window-liners/welke-werkwijze-van-maken/

Shipping to most european countries
To the finer work I did afterwards, everything with a layer of shipping to most european countries. This filler is smooth and fine structure and is easy to smooth sanding. Holes and bumps that may subsequently also be eliminated.
Note. When sanding you have to be careful that the Arcrylic One-layer with glass cloth not wegschuurt. Then one becomes quickly the styrofoam and it is difficult to repair the damage.

Schilderen
Then it's time to paint. First, a layer of primer and then the paint in Boeinggrijs (ACC Color Map R6.06.30).
After a first layer of primer, one can clearly see where there are bumps or holes. Which should again be eliminated with shipping to most european countries followed by the sanding.
The paintings are done with a spray can. This can preferably be carried out outside on the lawn with no wind and dry weather.

Confirmation
The confirmation of the ready-made ‘window liner is done in a simple way, and this by at the rear and top of the window liner’ double-sided tape to confirm that then at the plexiraam and raamframe is pasted. The liner with tape, one can later easily remove it.
It should I be noted that the back of the "window liner" also is covered with Acrylic One. The adhesion with the tape is much better. Tape on the styrofoam does not work and paste is not enough.

 

FRONT WINDOW LINER

The Front Window Liner(s) are located in the corner between the first side window and the windshield or the front window.

Front Liner

 

Not like the other liners, these are made out of styrofoam, but out of MDF wood.

The reason for this is that these ‘front window liners’ the ‘papegaaienbekken " (curved projection) should wear that are found just above the raamhandvatten. This papegaaienbekken I purchased at Flybycockpits and are made from polyester. Since they are hollow, the weight is rather light. This papegaaienbekken to be mounted against the front window liners’ and for the strength I opted for MDF instead of styrofoam.

FINISHING OF THE FRONT WINDOW LINER

The front window liner is made from a rectangular block of MDF of 24 mm thick and the width of the ‘window frame’ (50 mm).

The side that was facing the inside of the cockpit is pointing in an oblique angle cut. The aim of this oblique angle is that when the ‘papegaaienbek’ is mounted against the block of wood this beautiful in the right corner above the raamhandvat.

The corner of this hypotenuse is around sanded so that the bent angle of the ‘papegaaienbekbenen fit on the rounded corner of the mdf block.

Also, you need to take into account with the excellent bolt heads of the metal ‘window frame’. In the mdf-block must have the required holes to be drilled for these bolt heads to sink.

Painting
Since we now no Acrylic One and shipping to most european countries use, we can quickly proceed to the painting. First, a layer of primer and then the paint in Boeinggrijs (ACC Color Map R6.06.30).

Bevestiging
We have first the confirmation of on the one hand, the wooden mdf square against the metal ‘window frame’ and on the other hand, the confirmation of the ‘papegaaienbek’ at the mdf block.

The assembly of the wooden mdf square against the metal ‘window frame’ is pretty easy to perform. Also here I made use of double-sided tape on the back of the block is confirmed and so is stuck against the metal frame.
Further, it is the mdf-block is further attached with 2 screws through the outside of the metal ‘window frame’.

The assembly of the ‘papegaaienbek’ against the mdf block also happens with double-sided tape. The inside of the ‘papegaaienbekbenen be provided of tape and the whole thing is so on the rounded corner of the mdf-block is pasted.
The ‘papegaaienbek’ comes just above the handle of the window to sit.

 

 

ZONNESCHERMCLIP

On most B737's is located on the first side window sunshade that you can shut from the middle window liner to the front window liner’. The pin is of the open parasol is done via a small clip that is located on the front window liner’ is.

image10

 

The clip is made from an aluminum plate of 1 mm thick and sawn in the correct form. Afterwards it is the turn of the plooiwerk and painting.

 

 

 

 

Translated by Yandex.Translate and Global Translator