We finished off the installation of the rubber gasket strips on all the rafters and also the complete circuit of the outer rim of the skylight.
All-gaskets-fitted
Then in the workshop, we started the task of making aluminium end caps for all our 33 rafters, to cover up the cut ends and also hold in the polycarbonate sheets too. The bar manufacturer sells end caps but they are over large and would cost us £150!
We took a T shaped aluminium bar, 50mm across by 25mm deep and using a drill press and a core drill bit, cut out 50mm circles to end up with a flat slightly offset circle with a sticking out tab behind it. The tab will be screwed into the ends of the rafter glazing bars before we install it.
End-cap-cutting
End-Cap-2
End-Cap-1
Tomorrow, we will finish off this job, smoothing the rough edges and cutting the tab down to 30mm wide to allow these end caps to slide in and will have a screw to self -tap into the aluminium rafter bar to lock it down.