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Convert Hatch to AC & Roof Patch
(Search for the thread, title above for additional photos & rivet info)
Pics while deleting Hatch, Warning Lights, Strobe Light & Passive Vent
7" Light delete: 16g patch is applied to the interior side for a more flush & subtle finish.
Sealed factory screw holes with one pass of fiberglass, sanded and primered. Primered disks held with clecos, as rain is imminent. I may skim and...
*From inside, I piloted through each predrilled disk, with a 5/64" bit. Then go outside to step up hole size, using 7/64", 1/8", 5/32", & 3/16" bits....
(right)Drilling the first two of six 5/64" pilot holes. Step up bits/holes, then we add clecos (left) Repeat on remaining four, from pilots to...
I removed, cleaned & sanded the disks. Then black primered their 'out' sides. Later the rain came, interrupting my patch sanding, so I temp-covered...
The factory holes have been flattened, taped, fiberglassed, sanded. From inside, you can make out the reflection of eight, fiberglass dots in the...
This photo shows the screw clamp and the clecos On the left patch, the factory screws holes are temporarily used (by 10-32 machine screws) to...
Rear warning light delete A more attractive meathod
Intended patch location (1 of 8). Using the existing screw holes to temporarily secure each 6" disk, while working, with 10-32 nut/bolt/washers.
Eight 6 inch 16 guage Galvannealed disks, for front & rear Caution-Light delete Once again provided to us by EastCoastCB & family. Thank you. ...
Immediately after installing the last cleco. I removed the first one in and began to replace each cleco with a 3/16" stainless rivet. The blind end...
While not photogenic, the shade provides a cooler workspace. Using the trace marks a guide, I applied two continuous beads of Dynatron 550, one...
Drilled 16 new holes through the patch/template using four sizes of drill bits & clecos as I continued. Marked all orientations in pencil, now...
Finished metal patch, after riveting, before any finish coating is applied.
*Replacing each cleco with a "buttered" rivet. A thin bead of Dynatron 550 is applied around the rivet prior to tapping it in.
I removed the clecos, cleaned both surfaces with soap & water. I then applied a continuous bead of Dynatron 550 to the face, 3/8" from the patch...
Passive Vent Delete: Drilling one rivet position at a time, first though the 'template'/patch with 7/64" then reaming w/ three additional bits to...
Drilling the roof patch for the passive vent. Measured and marked piece. Secured to table with C-clamps & wood scraps. Dipped bits in cutting oil...
Passive Roof Vent removed. Cleaned roof sealant using wire wheel & sander. Flattened volcano holes with block & hammer, filled screw holes with...
We used an electric wench to ramp the a/c up. Having worksite a/c sooner than later, makes for cooler activities in the Florida heat. Houghton...
Checking for storm leaks: Photo taken during an all day rain storm. (Dry) Must be a good gasket as I still haven't added sealant to the outside. I...
Dehumidifier-Heat-A/C unit secured in the arch center (unlike the factory hatch hole)
The ac duct (14" wood frame) is now supported by the steel supports via 1-1/4" coated deck screws. Sealed between the wood/metal contact using PL...
Secured the repurposed steel ehatch supports for the wood AC frame. Left a 3/16" gap between the outer skin and the steel frame supports to reduce...
C-clamps lightly holding frame to hole. Hand bumped until center, flush, plumb, parallel. Marking drill holes for the side supports, which...
 
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