What the !!! It stopped raining for a couple of days so I picked up where I left off.
The shutter had been under the tarp for a week, in the rain and unpainted so it was moldy and some of the laminates where pulling apart. Reglued and clamped the crappy bits, sanded it off and undercoated. Got it leveled in the dome and glued it in at last. I had already glued in a few triangular reinforcement blocks inside and screwed the shutter to them as well as glueing it to the foam. The inside of the window is about 650mm wide.
Made up a half ring for the window. Didn't pay enough attention to detail here so I ended up with joins in the top and bottom layer right on top of each other. After I routed it and picked it up I found this out when it snapped. Bugger .. Had to join 2 bits to get the lenght for one side of the window. Not to worry, it works, patched the bits together with glue and a metal tie.
Made up a quick lower window out of offcuts to get the measurements for the main window. The lower window will be hinged so it can swing open for when I need to drift align.
The sliding window works, unbelieveable, this was my biggest worry. I'll be installing some guide wheels that I have, under the curved bits, so it doesn't rub on the track and eventually I'll cut those cross bars out as they will definately hit the back of the dome once it's rendered. Wood cross bracing will go in instead.
Next is the render on the dome. Looks like lots more rain coming so I have just put a final coat of arcylic on the wood and the tarp goes back on for who knows how long
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I also painted the dome with the rock texture paint so the render will key to it. The dome feels like course sand paper now.