Through Coach Roof hole preparation

Use a dremmel tool to sand around the edges

Epoxy the bare edge of plywood  with slow drying epoxy for moisture protection and allow to cure for 24 hours then sand with 80 grit sandpaper to give the sealant some tooth to adhear to

Backing Frame preparation

Remove old backing nuts from backing frame- first try to screw in bolt and push them out.  For the more stubborn ones, a drill can be used

Use a razor blade to clean old sealant off of backing frame

Redrill the holes using a ‘G’ size drill bit and use a reamer to clean out the holes just a bit, if due to corrosion the hole ends up too loose a bit of “gel superglue” will hold them in place while assembling.

Use a rubber head hammer to nail in the new backing nuts (order from Trend glass if original pre 1991 windows) – It is recommended to do this over a piece of wood with a hole the next size drill bit up to allow for a place for the backing nut to go

Supplies

Large area plastic drape

10+ rolls of painter’s tape (5 each of the delicate and normal types-multiple sizes are useful)

Latex Gloves (3 boxes)

25 tubes of AbroSil 1096 (White) Silicon Sealant (contact Oyster for details)

Caulking gun from England or standard large American Caulking gun where the pressing mechanism can be changed out for a 1¼  size washer (the tubes are as long as the American large caulking tubes, but have the same diameter as American small caulking tubes.

“G” Size drill bit

Scotch Brite dremmel tool attachment

Acetone

Qnty 192 backing nuts

Qnty 200 metric bolts 30mm long 5mm diameter

Qnty 50 metric bolts 35mm long 5mm diameter

Full roll brown paper

Epoxy

Sanding dremmel tool attachment

Rubber tipped hammer

?? drill bit for starting holes

?? countersink bit

Lots of paper towels

Very patient girlfriend who really wants a steak

Scissors

Pen

Right angle drill

Razor blades

Preparation

Install window (dry) and backing frame

Insert bolts one by one and make sure they engage 2.5-3.5 threads of the backing nut – if not try the next size up.  It is important that the screws do not bottom out either.  If they do, the bolts may have to be cut to an intermediate length

Use blue tape on the window to mark any locations where different size bolts are used

While window is in place, tape around the outside as close as possible but make sure no tape gets under the frame

If the window will be sealed in the next few hours, the holes can be countersunk at this time with the 90 degree countersink.  The goal is to have the bolts lay almost flat against the frame.  Make sure not to countersink too far.  Check the fit of the bolts again

Remove the window and backing frame

Using a razor blade, scrape away any sealant left over on the