H31468
544 Removal of Window Gap Filler
May 1/74 Figure 402 56-11-21
Page 403
BOEING PROPRIETARY - Copyright . - Unpublished Work - See title page for details.
H26912
Window No. 3 Installation 544
56-11-21Page 404 Figure 403 BOEING PROPRIETARY - Copyright . - Unpublished Work - See title page for details. May 1/74
(1)
Check that silicone rubber insert bushings (2) are inserted in the bolt holes in the window assembly (1).
(2)
Treat the bolt shanks with a corrosion preventive compound just prior to installation.
6. Install Window No. 3
A. Install window in frame.
(1)
Install retaining bolts (3, Fig. 403).
(2)
Install rubber cushion strip (4), metal backing plate (5) and support clip (6).
(3)
Install self-locking hex head nuts (7), finger-tight at this time.
(4)
Torque each nut 20 to 25 pound-inches only using a staggered sequence, diagonally back and forth across window in a criss-cross pattern. (See Fig. 404 for typical nut torque sequence.)
CAUTION: OBSERVE THE SPECIFIED TORQUE FOR BOLTS AS DAMAGE CAN RESULT IF THE TORQUE IS EXCEEDED.
NOTE: Rubber cushion strip causes a torque drop. Recheck torque until a stable reading is obtained.
Pressurized flight tends to bed any newly installed fixed window down in its frame. As a result, after initial pressurization if leakage occurs the attaching nuts should be checked. Any loose nut should be retightened to a torque of not more than 5 pound-inches, with the checknuts removed. Damage can result if this torque is exceeded. Replace and tighten the checknuts, while the attaching nuts are being held. After this occasion no further retightening should ever be done unless water or air leaks occur, in which case, retightening of attaching nuts should again be limited to a torque of 5 pound-inches. For self-locking attaching nuts, the 5 pound-inches is the torque above the run-on torque for the nut.
544
Nov 01/75 BOEING PROPRIETARY - Copyright . - Unpublished Work - See title page for details. 56-11-21 Page 405
CONTINUE IN THIS MANNER, ALWAYS PROCEEDING TO A FASTENER WHICH IS MIDWAY BETWEEN TWO INSTALLED FASTENERS AND ON A SIDE OTHER THAN THAT IN WHICH THE LAST ONE WAS INSTALLED
NOTE: THIS IS A SAMPLE PATTERN, ANY SIMILAR PATTERN WITH THE AIM OF TYING DOWN THE WINDOW PERIPHERY AT AS MANY WIDELY DISPERSED POINTS AS POSSIBLE AS EARLY IN FASTENER INSTALLATION AS POSSIBLE WILL SUFFICE.
H30752
Pattern for Typical Window Fastener Installation 500
56-11-21 Figure 404 May 15/67
Page 406
BOEING PROPRIETARY - Copyright . - Unpublished Work - See title page for details.
B. Apply masking tape over outside gap between window and skins to prevent contamination prior to filling with nylon cord and smoother.
C. Remove strip of masking tape immediately over gap at outside edge of \window. This can be done with a sharp knife or equivalent so as to leave strips of masking tape protecting the edges of the gap.
D. Insert a clean dry nylon cord, slightly longer than window perimeter, in bottom of gap at outside edge of window. The two ends should meet in the upper aft corner of the window frame and overlap at approximately 0.5 inch.
NOTE: To ease insertion of cord, stretch it slightly and tamp down into gap with a spatula if necessary.
E. Inject aerodynamic smoother into the gap by means of a flow gun or with a spatula until the gap is completely filled. (See figure 405.) Do not trap air under the smoother.
CAUTION: SMOOTHER IS AVAILABLE WITH SEVERAL WORK LIVES TO SUIT A VARIETY OF JOBS. STEPS E, F, AND G MUST BE COMPLETED DURING WORK LIFE SELECTED.
H31549
500 Application of Gap Filler
May 15/71 Figure 405 56-11-21
Page 407
BOEING PROPRIETARY - Copyright . - Unpublished Work - See title page for details.
F. Remove excess filler, while still wet, with a tool until just level with the masking tape.
CAUTION: DO NOT ABRADE METAL OR GLASS SURFACES.
G. Remove masking tape from edges of gap and protective cover from outside surface of window. Smoother material lifting at edges of the gap can be smoothed over with a tool.
7. Restore Airplane to Normal Configuration
A. Install trim panels and crash padding where necessary. Refer to Chapter 25, Control Cabin Equipment.
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