For those not familiar, the interchangeability of 8-32 screws where 10-32 screws should go makes this sort of error very easy to do. They go in right and can fe

For those not familiar, the interchangeability of 8-32 screws where 10-32 screws should go makes this sort of error very easy to do. They go in right and can feel right as they come tight. The only real clue can be a rattly feel in the hole. Often, switching like-for-like is a great way to work -- it can often be more reliable than documentation itself. The best way around this problem would seem to be installing the window from the inside (relying on the airframe instead of the fasteners), but I bet there was a defensible reason for that choice, too. A moral of the story could be that if documentation and reality don't match on a safety-critical part, one must simply stop operations until the question is resolved.