Triangle Window Frames

[aviator79]

Hoping for some help here. My triangle window frame pieces don't align with the door joggles. I have the narrow end of the frame pieces to the aft. On the left top, there is a little gap that I think I can close okay by flexing the Aluminum.

On the lower right, however, there is nearly 3/8 of an inch gap. I could bend the metal and blend it all with Super Fil and Hysol, but then the plane of the frame will not be flat, and I worry the window won't seat correctly. Am I doing something wrong here?

Top left:


Bottom Right:

[efwd]

I tried to look at my photos to post but just don't see one good enough. The material is very flexible thankfully. I pulled the surfaces together, held it with a clamp and drilled a single hole, and threw a rivet through it. If I remember correctly, I dimpled the two pieces and put a flush head rivet in it. Don't put it to close to the inside edges because you need that space to put the plexiglass in. As you suggested, I had to use Poly Fill to dress up the surface to accept the fabric. I really can't tell from the outside now that the fabric is on.
Eddie

[aviator79]

I tried to look at my photos to post but just don't see one good enough. The material is very flexible thankfully. I pulled the surfaces together, held it with a clamp and drilled a single hole, and threw a rivet through it. If I remember correctly, I dimpled the two pieces and put a flush head rivet in it. Don't put it to close to the inside edges because you need that space to put the plexiglass in. As you suggested, I had to use Poly Fill to dress up the surface to accept the fabric. I really can't tell from the outside now that the fabric is on.
Eddie

Do you recall how big the gap you had to close was Eddie?

[efwd]

Your top gap is nothing, Its similar to mine. Your bottom one is similar as well best I can recall. Your photo may be zoomed in enough that I can't really tell how much it is gapped. not a lot of reference in it. Mine was pretty good size, more than your top by a long shot. I believe what your worried about is the plexiglass not sitting flush inside the frame? I may have had a bit of a misfit but I did'nt even notice. I used the double sided tape used on the door frames to seal the window up and it all came out nice.
Eddie

[aviator79]

I just went and squeezed and tweeked and adjusted and I think it's possible to make it work. The hard part will be holding it all together to drill, glue and rivet. The geometry makes clamping difficult.

[Esser]

You can see mine on page 8 of my build