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How to Seal a Polycarbonate Plane Canopy

The shatter-resistant nature of polycarbonate makes it a common material for plane canopies. Sealants used to seal the durable material need to stand up to the pressures of high altitude and the high speeds associated with air travel. Caulking and other sealants used around your home or vehicle will not withstand the constant change in pressure and speed during flight. Even when using the correct type of sealant, you need to prepare the area around the window without causing irreparable damage to the surface of the polycarbonate.

Things You'll Need

Polycarbonate safe solvent
Lint-free rags
Canopy sealant
Cardboard
Metal putty knife
Syringe

Instructions

- 1
  Pour a polycarbonate safe sealant on a clean lint-free cloth. Wipe the area where the polycarbonate meets the plane fuselage with the solvent dampened cloth. Repeat the procedure with a second clean lint-free cloth. Dry the cleaned area with a third cloth to ensure no contamination remains on the two surfaces.
- 2
  Pour part-one of the canopy sealant on a clean piece of cardboard. Mix the first part of the sealant thoroughly with a metal putty knife. Repeat the procedure with the second part of the canopy sealant. Combine the two mixed parts of the sealant until you have one evenly colored fluid.
- 3
  Remove the plunger from the back of a syringe. Fill a syringe with the mixed sealant using the blade of the metal putty knife. Return the plunger to the back of the syringe. Push the plunger forward slightly to remove air from the syringe needle.
- 4
  Place the tip of the syringe in the seam between the polycarbonate windshield and the fuselage. Push the plunger toward the front of the syringe to dispense sealant in the seam. Pull the syringe while continuing to push the plunger. Move steadily along the seam to create an even seal.
- 5
  Allow the sealant to cure for 48 to 72 hours before flying the plane.

Aviation