Section 32, Windshield / Canopies, SeaRey, LSA

Progressive Aerodyne, Inc.

3801 State Rd 19
Tavares, FL 32778

Revision Description Remarks Date

01 Initial Creation 10/31/2012
02 Update Edited 11/21/2012
03 Update Edited 3/04/2013
04 Update Pg 4, changed method of securing the Hatch Cover 9/9/2013

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1.0 Scope
This document will detail the steps necessary for final assembly of the Windshield / Canopies.

2.0 Applicable Documents

N/A

3.0 Requirements
3.1 Equipment
3.1.1 The following tools will be necessary to perform this procedure:
 Awl or Adjustable Wrench
 Drill Bits, Jobber Length, 3/16”
 Drill, Electric, or Cordless
 Hammer, Plastic Tip
 Marker
 Open End Wrench, 3/8”
 Open End Wrench, 7/16”
 Open End Wrench, 1/2”
 Socket Set, SAE, 3/8” and 7/16” sockets

3.2 Materials
The following general supplies will be necessary to perform this procedure:

 Lacquer thinner (Cleaning labels off of parts)

 Protective gloves

3.3 Procedure (See the following pages)

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 Section 32, Windshield / Canopies, SeaRey, LSA

Nose Deck

Hull

Rivet Nose Deck

Figure 1. Final Installation of the Nose Deck

Note: Make sure all final work is completed in the Nose area before closing up

1.1 Set Nose Deck with Integrated Panel, Fiberglass (5340-045) in place over the Hull. Start at forward “V” and seat the Nose Deck into its
best fit position. Nose Deck fits over hull.
1.2 Drill a 1/8” hole in each side of the nose “V” and install a Cleco. Hole is 1/4” above edge of Nose Deck lip.
1.3 Work your way back 12” at a time, going back and forth, until you get all the way to the back dash area.
1.4 Measure and mark every 2-1/2” between the 12” marks/Clecos installed.
1.5 Drill a 1/8” hole in each of the 2-1/2” marks.
1.6 Add an additional hole to the rear for increased strength.
1.7 Install Rivet ABL4-4A (L-44) in all of the 1/8” holes.

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 Section 32, Windshield / Canopies, SeaRey, LSA

Nose Deck

Retainer
Washer
Hatch Cover

Cam Lock catch Hatch Gasket Cam Lock screw

Figure 2. Installation of the Nose Deck Hatch

2.1 Lay the Hatch Cover into position centering and taping into place on the Nosedeck.
2.2 Drill a 1/4” hole into each corner of the hatch cover right through into the Nosedeck.
2.3 Remove the hatch cover. Open up the 1/4” hole in the nosedeck to a 3/8” hole in (4) locations.
2.4 In the Nosedeck, take a Camloc Receptacle (#212-12N) and lay it upside down center the main opening of the Camloc with the ¼” hole below.
Mark for the two rivet locations. Drill the two rivet holes out with a 3/32” drill bit. Do this in (4) locations. Countersink the rivet hole from the top.
2.2 Install (4) Camloc Receptacle (#212-12N) to the four corners of the Nosedeck hatch opening from the bottom side of the hatch opening.
Secure each Camloc with (2) Rivet CCR-SS-3-5 (#264CR35).
2.3 On the top side of the hatch cover drop in (4) Camloc Fastener 2700-SS (#2700-8S) and on the back side press on a Camloc Retainer
Washer (#2600-LW).
2.4 Install Hatch Gasket (5340-51) around the perimeter inside edge of the hatch opening. Peel the adhesive strip off the gasket and apply the Hatch
Gasket starting and finishing at the forward center of the opening. Apply a bead of caulk at the gasket joint.

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 Section 32, Windshield / Canopies, SeaRey, LSA

Nose Deck

Nose Deck
Hull Side Angle Cockpit
Side
Screw Panel

Hull
Cockpit
Side
Hull Side Angle
Panel

Figure 3. Installation of the Lower Canopy Track

3.1 Set the Cockpit Panel Side Left (53120-040) and Cockpit Panel Side Right (5310-041) into position. Sit the top edge of the panel on the
Hull Side Angle pushing the forward top edge in between the Hull Side Angle and the Nose Deck.
3.2 Install Screw, #10-32 x 3/4” Dome Head (S75-10-32) into the side of the forward end of the canopy side rail to the Nose Deck. Drill a
3/16” hole that will catch all three components to tie them together (Hull, hull side angle and Dash) using the Screw, #10-32 x 3/4” Dome
Head (S75-10-32), Washer AN3, Hull, Hull Side Angle, Nose Deck, Washer AN3, Nut AN3, and tighten.

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 Section 32, Windshield / Canopies, SeaRey, LSA

Canopy Windshield Tube

Track,
Lower Threaded
Insert

Cockpit
Side
Panel

Rivet SBL44

Side Angle

Figure 4. Installation of the Lower Canopy Track

4.1 Sit the rail on top of the Cockpit side panel and side angle. Position so the Canopy Track, Lower (5610-008) is 31” from the face side of
the upper bulkhead cross tube to the front of the canopy track. At the aft end of the track have it spaced away from the turtledeck by ¼”.
4.2 Drill 1/8” holes down into the slot of the rail into the Cockpit Side Panel and Hull Side Angle. Use (5) Rivet SBL4-4 (SL-44), one on each
end and space others evenly to secure the Track.

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 Section 32, Windshield / Canopies, SeaRey, LSA

Windshield Tube
Threaded
Insert

Allen Bolt

Figure 5. Installation of the Windshield Tube

5.1 Remove 1” from both bottom ends of the Windshield Tube (5610-001).
5.2 Set the Windshield Tube at the forward edge of the canopy rail. Drill a 1/4” hole through the vinyl side panel and angle side rail.
5.3 Install a Bolt, ¼-28 x ¾”, Allen SS (#B075-428A) from bottom side with a Washer, AN4 (#N4W). On top side thread on a 7/16” Aluminum
Threaded Insert (AL-23DC).
5.4 Repeat on other side.

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 Section 32, Windshield / Canopies, SeaRey, LSA

Windshield Support
Windshield Support

Windshield Tube
Attach Plate

Figure 6. Installation of the Windshield Support

6.1 Remove the rear “ears” from the Windshield Support (5610-002) so the total length is 23”.
6.2 Install the Windshield Tube Attach Plate (5610-018) to the Windshield Support (5610-002) at the forward side. Drill (2) 1/8” holes on top
and (2) on bottom. Install Clecos.

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 Section 32, Windshield / Canopies, SeaRey, LSA

Windshield Support

Canopy Track, 53”

Rivet SBL44

Windshield Support

Rivet SBL44

Figure 7. Installation of the Upper Canopy Track to Support

7.1 Install Canopy Track, Upper 53” (5610-009) to the side of the Windshield Support (5610-002). Install a Cleco. Drill one 1/8” hole 1” from
forward end and drill one 1/8” hole 20” from forward end. Repeat on other side.
7.2 Insert the top center of the Windshield Tube (5610-001) into the front slot of the Windshield Support
7.3 Remove the Clecos from the top of the Attach Plate. Hook the Windshield Tube into the slot on the forward end of the Windshield Support
and hook the Windshield Tube Attach Plate (5610-018) over the Windshield Support.
7.4 Install Rivet SBL44 (SL-44) into the (2) top holes in the Attach Plate to the Windshield Support.
7.5 Find the center of the Windshield Tube. Drill an 1/8” hole in the forward center of the Windshield Tube Attach Plate (5610-018) and into the
Windshield tube. Install a Cleco.

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 Section 32, Windshield / Canopies, SeaRey, LSA

Figure 8. Installation of the Windshield to the Nose Deck

8.1 Install Windshield (5610-016) so the front “V” fits in the notch of the Nose Deck. Drill a 3/16” hole in the center and Cleco.
8.2 Work your way out, going rearward and add (2) more Clecos at 12” and at 24”.
8.3 Make marks on the Windshield where it hits the side angles of the cockpit so this can be trimmed. Also mark the angles to be trimmed off.
8.4 Use an angle cutoff wheel to remove side angle plate material.
8.5 Finish drilling the remaining 3/16” holes on the lower front Windshield, every 2-1/2”.
8.6 Remove the Windshield and debur all the 3/16” holes to prevent cracking.

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 Section 32, Windshield / Canopies, SeaRey, LSA

Windshield Tube

Figure 9. Installation of the Windshield Tube to the Windshield

9.1 Re-install the windshield with Clecos and clamp the Windshield to the Windshield Tube (5610-001).
9.2 From the upper center of the Windshield measure out 4” on each side. Then measure every 2-1/2”, following the Windshield Tube.
9.3 Drill 1/8” holes at all the marks into Windshield right into the Windshield Tube.
9.4 Remove Windshield and debur all the holes, inside and out.

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 Section 32, Windshield / Canopies, SeaRey, LSA

Windshield Tube

Rivet SBL44

Figure 10. Painting and final Installation of the Windshield

10.1 On each lower end of the Windshield Tube, drill a 1/8” hole on the aft side, 1-1/8” up from bottom.
10.2 Install a Rivet, SBL44 (SL-44) to hold Windshield Tube to Threaded Insert.
10.3 Paint edges of Windshield black or white– tape off – while the windshield is off.
10.4 Re-Install Windshield with Clecos. Rivet in place with Rivets, AB6-8A (P68) on the forward edge into the Nosedeck. Use Rivet(s) ABL4-4A
(L-44) on the Windshield Tube.

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 Section 32, Windshield / Canopies, SeaRey, LSA

Silicone Caulk

Rivet SBL44

Figure 11. Installation of the Windshield

11.1 Tape off lower front Windshield and caulk. Caulk lower ends.
11.2 Install Rivet SBL4-4 (SL44) in lower corner of Windshield into forward track.

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 Section 32, Windshield / Canopies, SeaRey, LSA

Canopy Track, Upper

Location 3”
Location 29”

Figure 12. Installation of the Upper Canopy Track

12.1 Secure the Canopy Track, Upper (53”)(5610-009) with (2) Clecos. Drill 1/8” holes at 3” and at 29” approximately from aft end securing to
the Root Support Forward and Root Support Mid.
12.2 Check the alignment of the Track so it is straight, with no bend up and down or in and out. Remove the Track and make any adjustment
by adding spacers or shims.
12.3 Reinstall the Track using Rivet, SBL4-4 (SL-44). If a larger gap, use Rivet AB6-8A (P-68) instead.
12.4 Remove the cleco in the forward center of the Windshield Tube Attach Plate (5610-018) and install a Rivet, SBL44 (SL-44) through the Windshield
Tube Attach Plate into the Windshield tube.

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 Section 32, Windshield / Canopies, SeaRey, LSA

Canopy Guide,
Upper

Canopy Guide,
Lower

Figure 13. Installation of the Upper and Lower Canopy Guides

13.1 Install the Canopy Guide, Upper (5610-007) and Canopy Guide, Lower (5610-003) into the Upper and Lower Tracks. Check to make sure
the Guides slide smoothly. (Note slot in Canopy Guide: bottom guide slot is on top and to the outboard edge, top guide slot is facing
outboard and is at the top edge)

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 Section 32, Windshield / Canopies, SeaRey, LSA

Figure 14. Installation of the Lexan Sliding Canopy

14.1 Trim 2” of the protective film from the Canopy, Sliding, Lexan (5610-010) on the top and bottom, inside and out.
14.2 Install the Canopy Window into the Upper and Lower Guides.
14.3 Hold the Canopy Brace, Forward (5610-005L & 5610-006R) and Canopy Brace, Aft (5610-004) up to the Windshield Tube on forward side
and on aft end against the Turtledeck. Check against the Canopy window final arch. Bend slightly on each to fit desired shape.
14.4 Mark the Canopy Window at the desired locations to get the Canopy to match the shape of the Turtle Deck at rear and the Windshield at
front. Trim slow, at small increments. Keep test fitting until correct fit is reached.

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 Section 32, Windshield / Canopies, SeaRey, LSA

Figure 15. Installation of the Canopy Braces

15.1 Apply a small amount of contact cement to the contact surface of the Windshield Tube and install Weather Seal, 3/4” Self-Adhesive (5610-
024).
15.2 Trim the height of the Canopy to get the correct arch.
15.3 Bump the Canopy up to the Weather Seal on the Windshield Tube and scribe a mark so it matches.
15.4 Cut the Canopy and test the fit again.

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 Section 32, Windshield / Canopies, SeaRey, LSA

Weather Seal, ¾”

Weather Seal, ¾”

Figure 16. Installation of the Weather Seal to Windshield

16.1 Install Weather Seal, 3/4” Self-Adhesive (5610-024) to the forward end of the Turtle Deck along the whole arch, covering over the Turtle Deck
Upholstery.
16.2 Cut the top and bottom Canopy Guides to the overall length of the window.
16.3 Remove the Canopy and Guides together. Lay out on a flat surface. Drill 1/8” holes 1/2” in on each end Guide and then space every 2-
1/2” to 3-1/2” on the outside of the Guide.
16.4 Install Rivet, ABL4-4 (L-44). Note: make sure Guide is seated to the Canopy.
16.5 Install the Canopy Brace Aft (5610-004). Pull the Double sided tape and apply to the canopy aft edge. Drill a 1/8” hole 1/2” at each end on
outer side of Canopy. Install Rivet, ABL4-4 (L-44).
16.6 Install Canopy back into track.
16.7 Install Canopy Brace, Forward Left (5610-005) and Canopy Brace, Forward Right (5610-006). Set into position at 3/4” to 1” back from
front edge of Canopy and clamp. Drill 1/8” hole at 1/2” in on each end and add additional at 4” to 5” spacing.
16.8 Install Rivet, ABL4-4 (L-44) through Canopy into Canopy Brace Forward.

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 Section 32, Windshield / Canopies, SeaRey, LSA

Canopy Knob Windshield

Canopy Knob
Black Caulk

Weather Seal

Figure 17. Installation of the Canopy Knobs & Weather Seal

17.1 Install Canopy Knob (5610-021): Drill 3/16” hole in the forward end of the Lower Guide at 1-1/2” to 2” back.
17.2 Install Dome Head Machine Screw #10-32 x 1” (S100-1032) from inside through to outside, Screw on Canopy Knob.
17.3 Repeat at top 2” back, same as above.
17.4 Install Weather Seal ¾, Self-Adhesive (#5610-024) on forward canopy inside edge. Run a bead of black silicone caulk (#3230-033) between the
windshield edge and the Weather Seal ¾, Self-Adhesive (#5610-024).

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 Section 32, Windshield / Canopies, SeaRey, LSA

Paint

Bolt AN3-11A

Paint

Figure 18. Painting Canopy and Install of Canopy Stops

18.1 Paint forward and aft edge 1” of the Sliding Canopy with white or black paint. Tape off and paint 3 to 4 light coats with the final coat
producing a high sheen.
18.2 Install Bolt AN3-11A (N311A) with Nut, AN3 Lock (N3LN) at the aft end of the track for a canopy stop on pilot and co-pilot sides.

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 Section 32, Windshield / Canopies, SeaRey, LSA

Inside Shown

Cabin Window

Rivet AB4-3A

Figure 19. Installing Cabin Window

19.1 Trim back the protective sheet about 2” on both sides of the Cabin Window (5610-015) perimeter edge.
19.2 Peel back the carpet on the Turtle Deck about 2” so you can slide the Cabin Window between it and the Turtle Deck.
19.3 Install the Cabin Window between the carpet and Turtle Deck. Hold in place centered in the cutout of the Turtle Deck.
19.4 Drill a few 1/8” holes into the Turtle Deck and into the Cabin Window, spacing out just to hold into place. Cleco in place.
19.5 Mark holes every 2-1/2” and drill 1/8” holes. Remove the Cabin Window and debur all the 1/8” holes to prevent cracking of Lexan.
19.6 Install Rivet AB4-3A (AB4-3A).

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 Section 32, Windshield / Canopies, SeaRey, LSA

Figure 20. Caulk Cabin Window and Finish Interior Carpet

20.1 Caulk perimeter of Cabin Window (5610-015) on outside, color to match exterior color.
20.2 Contact Cement the carpet back into position on the inside.

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