Triangle Window Frames

[aviator79]

Hoping for some help here. My triangle window frame pieces don't align with the door joggles. I have the narrow end of the frame pieces to the aft. On the left top, there is a little gap that I think I can close okay by flexing the Aluminum.

On the lower right, however, there is nearly 3/8 of an inch gap. I could bend the metal and blend it all with Super Fil and Hysol, but then the plane of the frame will not be flat, and I worry the window won't seat correctly. Am I doing something wrong here?

Top left:
https://lh3.googleusercontent.com/n03PyMjZvGHHNeBU5tjLMtDPYw8BcUr3HOxzUTmgzr9kHl9TjF VfOtZXslYrJUWyXrXtNHREMJT9M-4AR2EXw9Uqi8VsKe8p1q1BBIhrMk27rrIY8CbX3F3SP5wF9Tpr zH31L2WY2IA=w700

Bottom Right:
https://lh3.googleusercontent.com/Ga8tPlCE6kqpmRMLsMkUnqjazhOGsAAgMkNtNExse6sPz1Sq4B KV4S9QLJnRLn1czIWb6M80ufkihM1H8bRX6c9ImXllcTCYgzsX JfSV6pMKBm4TjliMrOc_kpHLPoskBsOs9C5xRw8=w700

[efwd]

I tried to look at my photos to post but just don't see one good enough. The material is very flexible thankfully. I pulled the surfaces together, held it with a clamp and drilled a single hole, and threw a rivet through it. If I remember correctly, I dimpled the two pieces and put a flush head rivet in it. Don't put it to close to the inside edges because you need that space to put the plexiglass in. As you suggested, I had to use Poly Fill to dress up the surface to accept the fabric. I really can't tell from the outside now that the fabric is on.
Eddie

[aviator79]

I tried to look at my photos to post but just don't see one good enough. The material is very flexible thankfully. I pulled the surfaces together, held it with a clamp and drilled a single hole, and threw a rivet through it. If I remember correctly, I dimpled the two pieces and put a flush head rivet in it. Don't put it to close to the inside edges because you need that space to put the plexiglass in. As you suggested, I had to use Poly Fill to dress up the surface to accept the fabric. I really can't tell from the outside now that the fabric is on.
Eddie

Do you recall how big the gap you had to close was Eddie?

[efwd]

Your top gap is nothing, Its similar to mine. Your bottom one is similar as well best I can recall. Your photo may be zoomed in enough that I can't really tell how much it is gapped. not a lot of reference in it. Mine was pretty good size, more than your top by a long shot. I believe what your worried about is the plexiglass not sitting flush inside the frame? I may have had a bit of a misfit but I did'nt even notice. I used the double sided tape used on the door frames to seal the window up and it all came out nice.
Eddie

[aviator79]

I just went and squeezed and tweeked and adjusted and I think it's possible to make it work. The hard part will be holding it all together to drill, glue and rivet. The geometry makes clamping difficult.

[Esser]

You can see mine on page 8 of my build

[David47]

I had exactly the same problem on the passenger side Brian. The pilot side was ok. I made a new channel with an extended centre web to take up the gap and get a flat plane for the window. My gap was the same order as yours.

[PaulSS]

Does this link help at all? It's Jim's photos on door frames but I don't know if it'll answer your question as I'm a lurker and not a KF builder :)


Jim's Door Photos (http://www.teamkitfox.com/Forums/album.php?albumid=40)

[aviator79]

I had exactly the same problem on the passenger side Brian. The pilot side was ok. I made a new channel with an extended centre web to take up the gap and get a flat plane for the window. My gap was the same order as yours.

It's comforting to know others have run into the same issue. Josh's looks like he had quite a gap to make up as well. I might make some new ones, but raw stock isn't easy to find in our small town, and shipping can be brutal when trying to order online.

[Esser]

This is an area that I look at with every Kitfox I see in person and they are all the same. Try to minimize the gap, pop a countersunk rivit in each corner, and then super fill the transitions as best you can. As long as your window can sit flat, you’re all good.

[aviator79]

Just an update, the gap was large, but nothing some that could not be overcome with faith and Super Fil.
https://lh3.googleusercontent.com/qBqgJgrPsZHF0wLv9ojt-uCwg-_tPwri6H13EdKTJYL4vrudebLwQBpEIEX1fPRYBgCE3OkwTmDp VxRCuk9We6NHC1RLonpkaI31HqZUdF_aEgrhs8RbUfAw8ZcezR TihbgiANlnqMY=w600

https://lh3.googleusercontent.com/BnxpZKcWUcr_D8-IGRffIR6-wOPkXy3MIwKfIv4pwxKU1HcTrzmN_1xRcwvz-Nl2fWeuaoUMqNZsJaPz9ICqx2spH9rqyiVBqxPOZ_88BaE8Nko KPREXpU8Q-DWEI3CgMO93OXrWbko=w600

[efwd]

Yup, looks familiar.:)