Hey Guys, Just thought I'd share something I've learned. After building a Carbon Cub I've learned some new techniques for a number of processes and attaching windows was one of them. Knowing what I know now, I'd never use all those rivets on windows/doors/sunroof, instead I would use 3M acrylic foam tape,
http://highbondtapes.com/grey-25mil?gcl ... fgod6lgCbg, and stainless #6 stainless truss head screws with plastic washers under the screw heads. Cubcrafters use this technique to attached all their acylic/polycarbonate to frames and it is amazing stuff. I would go with the 1/4" tape for the rounded tube frames. With this stuff you won't need 3/4ths of the rivets you are currently using on your windows or sunroof. You'll only need rivets in the corners of straight runs and mid points of the window and door where the glass bends. Because its foam it will also absorb the vibration so you'll never have head popping off.
There is a technique to putting it on though:
1. Fit and drill window and frame as you normally would using clecos to hold it in place. Whether you uses rivets or screws make the holes 25-30% larger the the diameter of the screw or rivet.
2. Remove the glass and clean the frame with alcohol where the tape is applied. The tape is applied to the all sides of the frame which the glass comes in contact, DO NOT REMOVE THE RED LINER FROM THE TAPE AT THIS TIME.
3. At the each corner of the frame or end of each length of tape pull off a one inch tab of the red liner or what ever length you need to be able to accessed it when the window is clecoed back onto the window/door, installed on the fuselage and closed. Put some thought into how the tabs will be accessed.
4. Cleaco the window onto the frame.
5. From one of the tape ends (using the tab you started in step # 3) start pulling the red liner off the tape from under the window at a 45 degrees to the frame and remove clecos as you come to them on the frame. Replace the cleco after you've cleared the hole by about 3" and continue removing the red liner.
6. Continue removing the red liner on all other lengths of tape. Make sure the glass is pressed down on to the tape, remove clecos and replacing them with screws or rivets as you go.
7. REMEMBER!!! once the window is stuck to the tape IT IS REALLY STUCK! so take your time! It can be removed by a razor blade or running a small drill bit between the glass and frame but it is a pain to do.
Let me know if you have any questions.