Troy, I just finished rebuilding both my side windows. I used some old parts from my original windows that were in good condition and bought new ones where necessary.
The bottom of each window consists of a stiffener over either a one-piece (spot welded) frame or two separate side frames. The stiffener is Univair 415-53022-2 ($8.99 each) The Univair bottom frame is 415-53052-3 Qty 1 ($19.50) spot welded or Qty 2 415-53051. I used the Univair part on one side and a good two piece set on the other. The stiffener holds them together so it does not matter if they are spot welded or not. At the top of the Pilot side window the frame is a spot welded assy - Male Frame Univair 415-53024-10 $45.29 The inside handle 415-53048 Qty2 and the outside handle 415-53075-1 Qty 1, I made out of raw angle stock I bought from Aircraft Spruce and shaped with a 120 grit sanding wheel. I had bought new handles from Skyport and was disappointed with the quality. Mine came out much better. I fabricated the outside handle from a 3.5 inch length of 1/2 x 1/2 x 1/16 extrusion. The vertical ends are rounded to a 1/2 radius. The inside handles are 2 inches of 1/2 x 5/8 x 1/16 extrusion. I could not find this and used 5/8 x 5/8 which I sanded one side to 1/2 inch. (I did not have a bandsaw) The vertical ends are rounded to a 1/2 inch radius. The raw stock was about $3 to $5/foot and one foot is enough for the entire job. At the top of the Passenger side window are two identical frame pieces (sorry forgot to write the number in my notebook and the drawings are in the hangar) and the same inside and outside handles. I bought the glass from a local plastic house and had them cut it to size. I bought four (just in case) "Acrylic Sheet .060 x 19.75 x31.75" for $9.40 each then used the 120 grit sanding wheel to round the corners and round the side profile of all four sides as shown on the drawings. The drawings show the windows unequal lengths (both shorter) and slightly wider (7/8") but I copied my existing widows and I am happy with the result. With the new windows closed you can see the bottom frame/stiffener rivet line just below the window sill of the fuselage. I used special plastic drill bits from Aircraft Plastics and drilled the holes 75% larger than the rivet diameter. I also did not squeeze the rivets too tightly. One warning. The original drawings (from Bowling Green University) show the rivet holes in the top frames fairly far away from the edge of the window. Do not be tempted to move these holes outward, they are located so far inward so that the rivet heads clear the window track. Also the handles have to be back far enough the two frames can lock together without hitting the handles. I got the microfilm of the original Ercoupe drawings from BGU but the original Coupe windows had no bottom stiffener and the handle was a complicated four piece roller affair so make sure you make a drawing of your present windows before you disassemble them and note which side the rivet shop heads are. Also on my windows the rounded side of the bottom stiffener goes to the inside of the window. Overall it was time consuming but the final result looks great. I had just taken Sportair's metal working course in Sept and it was very useful in teaching me the techniques to rebuild the windows. I used the end of the course to drill out the rivets inmy old windows for parts. Good luck. David Abrams [EMAIL PROTECTED] http://www.ercoupe.com ---------- From: Troy P. Coker, III[SMTP:[EMAIL PROTECTED] Reply To: [EMAIL PROTECTED] Sent: Saturday, November 07, 1998 4:03 PM To: [EMAIL PROTECTED] Subject: Side Windows I am restoring a 415C. I need a set of metal brackets that attatch to the top of the plexiglass. If anyone has a pair for sale or knows where I can purchase a set, please let me know. Troy Coker Dallas, TX.
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