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N.  Micro-Gloss Cleaner, (Ref 20-30-31)
4.  Repair Outer Pane External Surface
A.  Use optical micrometer to determine if window thickness will permit rework.
NOTE:  Minimum pane thickness after rework must not be less than 0.265 inch for all outer windowpanes in fuselage.
B.  Check condition of seal. If window fogging or seal damage is evident, replace window.
C.  Mask window frame and exposed seal, with tape.
D.  Apply water spray, and remove loose dirt and abrasives with bare hand.
E.  Remove defects as follows:
(1)  
Remove minor clamshell surface chips, scratches, or surface crazing, with an abrasive paper or cloth appropriate to the surface starting condition (generally not coarser than 100 grit for gouges, deep scratches and severe crazing). Use ample water to keep the window surface cool and to flush away grit and acrylic material removed. A vibrating sander (approx. 8000 cpm) stroked with alternating 100% horizontal coverage, followed by 100% vertical coverage over the entire window surface works well. One to two minutes of coarse grit sanding will remove approximately 0.005 inches of acrylic from a window. Change abrasive paper frequently, flush well with water, and continue until all surface damage is removed and the surface appearance is uniform. Then continue for approximately one more minute to ensure complete removal of craze/cracks.

NOTE:  If the condition requiring repair is minor, start with a finer abrasive to reduce subsequent polishing time. Do not attempt to rework only a local part of surface area as this will result in optical distortion.

(2)  
Polish window with a graduated series of abrasive materials. Use 100 - 600 grit paper and micromesh cloths of 1600 - 8000. Continue each step until the polishing marks of the previous step are removed (normally 2-3 minutes). Use alternating horizontal and vertical strokes with the vibrating sander and make sure water flow is continuous.

F.  Check finished window dimensions.
NOTE:  Minimum window thickness must not be less than 0.265 inch for all outer windowpanes in fuselage.
G.  Remove water spray.
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56-21-0 Page 802  BOEING PROPRIETARY - Copyright . - Unpublished Work - See title page for details.  Oct 20/87 

H.  Finish polishing the window with buffing compound and a clean muslin or wool pad. If necessary, use coarse and fine compounds to obtain a high gloss. If a rotary buffer is used, wheel surface speed should be 3200 fpm for coarse compound and 4200 fpm for fine compound.
I.  Check window visually for optical quality. If distortion exists, repeat polishing procedure provided pane will meet minimum thickness dimensions after polishing.
J.  Wax exterior surface
(1)  
Minimum thickness of middle windowpane -- 0.157 inch.

(2)  
Maximum depth of defect in inner pane (dust cover) is 0.03 inch. Polish defects out by polishing entire viewing surface.

K.  Polish window with wax and cover with protective coating or tape.
L.  Reinstall window if removed for rework.
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Oct 20/88  BOEING PROPRIETARY - Copyright . - Unpublished Work - See title page for details.  56-21-0 Page 803 

PASSENGER CABIN WINDOWS PLATE (PLUG) - REMOVAL/INSTALLATION
1. General
A.  In converting from a passenger cabin window plate (plug) installation to a passenger cabin window installation, remove the plate (plug) as described in paragraph 3. To install the passenger cabin window, refer to 56-21-0, Removal/Installation.
2.  Equipment and Materials
A.  Cellulose Acetate Sheeting - Permacel Tape No. 76, Minnesota Mining and Manufacturing Tape No. 221 or Transparent Cellophane No. 600, Spraylat SC-1058R
B.  Masking Tape
C.  Cheesecloth or equivalent
D.  Aliphatic Naphtha - TT-N-95, Freon TF
3.  Remove Window Plate (Plug)
A.  Remove protective sidewall lining or grill to gain access to window (Ref Chapter 25, Passenger Cabin Lining and Insulation).
B.  Remove insulation pillow, if installed.
C.  Remove clip adjusting screws and remove the ten window retaining clips (detail A, Fig. 401).
D.  Disconnect grounding strap (if installed) from plate (plug).
E.  Remove window plate (plug) and seal.
CAUTION:  UNLESS PLATE (PLUG) IS TO BE IMMEDIATELY REINSTALLED, A PROTECTIVE COVERING OF CELLULOSE SHEETING OR EQUIVALENT, SHOULD BE APPLIED TO PLATE SURFACES TO PREVENT DAMAGE DURING HANDLING.
F.  Remove seal from plate (plug). This step is only necessary if the seal is torn or damaged in any way.
4.  Prepare Window Plate (Plug) for Installation
A.  Remove protective cover if installed, from window plate (plug).
　
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