Today was warm first thing. By "smoko" (morning tea) the temps were already in the mid 20's (degree C) and climbing. We therefore set to work on the canopy again. First task was some shaping / trimming of the front corners. We also removed about 1/16" from the sides to help it seat properly on the rails. Everything on the plexi has to be de-burred / edged before handling / moved to help reduce the risks of cracking - not a problem just slows the process a little. The band sander was working hard - but working well.
Also decided the ear cut-outs needed to be bigger. Another Rotor-broach application - this tool in particular continues to impress - it is a bit $$ but you can see the 'half moon' piece that is removed without issue - very clever. Then it was cleanup / deburring as usual.
Then it was taping the canopy down tight and rechecking everything.
The front profile looks 'OK' - it is very difficult to get it symmetrical (lots of funny compound curves in different directions) but good enough for the moment.
The sides were gaffer taped and then the sideskins were cleco'd on to help hold everything tight.
The back was clamped all over the place, both canopy to ribs, canopy to roll bar, roll bar to ribs. Also side rails to longerons to hold everything in a 'set place'.
Even the front has a temporary clamp.
Then it was commitment time - we drilled 4 locations trough the side skirts (as a template) through the plexi and just marked to the side rails.
Then the rear ribs were marked for all the screw locations.
This was then transferred through the plexi onto the '3M scotch tape' which is clear enough to be able to make out the marks whilst still protecting the plexi.
Then the rear locations were drilled off the fuselage - this means the plexi drill can go through the whole way and not have to touch the AL.
Then with everything mounted back up and clamped down, the rear rib locations were drilled with a #31 drill - this goes through the 1/8" plexi hole cleanly and provides a silver cleco location. We started in the center and worked both sides out and down in turn.
The side rails were next - same principle - side skin for template locations, through the plexi, mark the side rail only.
Then the side rails could be drilled out with the canopy off, we also finished drilling the canopy locations. Then lots of deburring / smoothing everything - particularly important for the plexi work.
All in all a good day, so far the canopy seems to be progressing in the right direction. Slow progress, and I know we are being (overly?) cautious but I would rather take our time on this bit. It is another example of where having an experienced voice would be helpful - you USA guys with dozens of builders at an airport really are very fortunate.
