One Window done

This Saturday I set out to referb the windows and the two openings on the east end of the copula.
The windows are a mess. They frame of the window is rotten and it has been fulled with sealer.

each window was riveted into the frame, then a separate piece of sheet metal was added and then the 

window was screwed to the plate.

I started with grinding the rivets and removing them.

After the rivets were knocked in , I started cleaning up the window.

The cleaning took a while.

Then I started to clean and repair the frame.

There were very messy

This picture shows the gap the existed and that was filled with caulk.

I decided to weld a filler piece into the frame then I went to work on the front and filled the gap.

After I welded the gap closed, I used a bit of the filler to get a smooth and even and waterproof look.

Once sanded, I primed and reassembled the window.

I will put the rest of the bolts in tonight.

Three more to go!

Window Two!

Lower roof edge

The lower roof edge is complete. The process took more time then I thought but it looks great. In the last post it showed the edge with the rivets and the before. Here is the before and after.

This is done in two sections.

The steel would have been harder to work if we had kept the full length.

After bending the steel parts, it was time to put them in!

I marked the entire side and dry fitted the part the best I could.

Once it was marked, It was time to cut.

Once the old part was removed, I had to clean all the rust from the interior area. I primed that area because it will likely never be seen again. ( At Least in my lifetime)

The shell and the frame had separated so I inserted bolts to close the gap and I welded the shell to the frame. I had to remove those bolts because those holes will be needed for the final attachment

I tacked the new piece in place

Ground down the welds and here you go! Just that easy!

I primed the new steel and got it ready for the next piece

The second part was very similar

Then comes the drilling

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And new bolts

Lots and lots of bolts