Canopy bubble drilling!

 Finalized the location of the canopy, taped it down and started drilling it to the frame today.

First I drilled the canopy frame bow in the front per the marked holes.  Must drill at the angle that is perpendicular to where the bubble contacts the bow.

Taped the Poo out of the canopy so it does not move.

Used 1/8" shims at the front to ensure that gap remains constant.

Ensured that the hole is concentric with the shaft.

And started drilling with the plexi drill.  Front to back and side to side.

Stopped for today because I did not want to push my luck.

Canopy bubble fitting

Now comes the fun stuff of working with the canopy bubble.  Always a risk of cracking one of the most expensive parts of the kit.  No pressure!

First is to remove about 3" of the protective film around the edges of both sides of the bubble.  Then to tape what remains down so that it is protected as much as possible.

There was a blemish just to the side of the factory cut hole in the bubble.  It kinda looks like that was supposed to be there as an indicator of where they should drill the hole.  Hopefully it is not that far off!

Tape up the side rails to help prevent scratches.

This tape gets layed out but not pressed on to help indicate where the canopy contacts the frame.

Tape up the canopy latch shaft hole that sticks up to help prevent scratches.

I noticed that the copilot side was sitting on the frame and it needs a minimum 1/8" gap.  First cut was completed.

The front corners needed a little trimming to allow them to clear the frame.  Easy peasy,

Then it was time to located the canopy and triple check all the measurements.

Ensuring the 1/8" gap between the front of the bubble and the top fwd skin.

Marking the latch hole to be able to make it more concentric with the shaft.

I made a Z shaped tool from a vinyl coated coat hanger that I used to press the blue tape down to the frame in the front.  I stuck it under the bubble between it and the frame and worked it across the hoop.  Worked great!  I then marked the tape per the KAI's.

Canopy latch and handle

Worked on the canopy latch handle today.

First is match drilling the exterior handle to the interior handle shaft.  Be careful to drill it straight.

Then the exterior handle gets drilled deeper for the tapped threads.

Then the first half of the handle gets enlarged for the screw clearance.

Then the shaft gets enlarged as well.

Then the exterior handle is tapped for the screw that holds it onto the shaft.  I can't believe this one little screw is all that keeps the handle from falling out and if it does, the canopy will be free to pop open in flight.  I don't worry about the screw shearing off but it is possible for it to vibrate out.  There is no mention of using loctite on this screw but you can be sure I will be.

Next the interior handle has to be rounded over in a few places. 

Then this spacer has to be installed onto the shaft.  It must be chamfered to allow it to clear the weld bead on the handle.

The fit was so tight that I was not able to just slide the spacer down the shaft.  I had to make a tool to help push it without damage.  I just drilled a hole in a piece of hardwood that was just big enough for the shaft.  Worked well.

Then they have you clamp the frame to the rollbar using the wood spacers that were included in the kit.

And they have you check that the latch interfaces properly with the latch block.

Canopy frame part 5

More work on the canopy frame.

The angle that eventually helps to hold the canopy bubble to the frame must be fluted to match the shape of the frame. It takes some serious fluting of these parts to get them into the right shape.  Just go slow and do a little at a time until it is correct.

Then they have to be match drilled to the frame.  The inside edge sits flush with the inside edge of the canopy frame.

TADA! I then did the other side.

Canopy Frame part 4, and interior color choices.....

More work on the canopy frame.

They have you install the gas struts at this time.

Then some shims are placed on the canopy rail decks.

Can't open this thing fully when it is in the garage.  :(

Had to bend the frame to match the shape of the fuse side..

I am going to do Rustoleum Hammered paint again on the interior.  Worked well on my RV-7 so why not.

Here are the colors that I have to pick from that may match my interior color choices:

The copper is too orange.  The Gold is too yellow.  The Dark Bronze is too dark.  In the end I settled on the brown.

Canopy Frame part 3

More work on the canopy frame today.

Weird but they have you match drill these parts together even though they are welded to each other.

And rivet them.

The canopy latch stop gets match drilled to the canopy frame.

And then riveted in place.