Long day in the hangar today, but an exciting one! I finally can officially say I’ve begun work on the canopy!

Step number 1 is to place the canopy frame in place, and ensure proper positioning. This is done in two ways. First you measure the canopy frame from the front. The foam insert should be approximately 3/4 of an inch behind the skin reinforcement shown here.

Next select four points on the frame. (Basically the corners). The points should be on the same position relative to one another. Here you can see the points I selected on the right hand side. I then mirrored these points to the left side. I measured these four locations to the joggle. And by joggle, I’m referring to the line where the canopy and canopy skirt will intersect. I also selected four points on the outside of the canopy frame and measured here. Finally, I used a level to check my sanity. (Don’t use the level as the primary method of positioning the canopy frame.)

After I was positive the canopy skirt was positioned properly I marked the forward cut line, and the points at which the rails intersected on both sides.

At this point, I needed to return my attention to the instrument cover. The next step requires the instrument cover be installed to check the fit of the canopy skirt after trimming to ensure there isn’t any contact between the forward foam reinforcement (used to measure the 3/4 inches above).

Here you can see the intersection from the fillet on the right side.

And the left side.

I installed all the nut plates so that I could be 100% sure the instrument cover was properly positioned.

Here is the canopy skirt after trimming with the instrument cover installed beneath. Note, that the cover does NOT go forward of the skin, and nests on the canopy cover. The result is a smooth transition.

I also did the initial trim on the right side in order to begin the hinge installation. Be careful. Always measure twice, and when cutting err on the side of leaving extra material. Its easy to make small adjustments with a dremel and file to remove a little more material.

At this point, there aren’t too many more pictures, or much to explain, however there was a lot of time spent. I carefully filed the forward intersection for a nice fit. This required multiple instances of installing the frame, and then removing. Each time checking for alignment. I do not need to make it perfect at this point, but my goal is to incrementally adjust this puppy with the end result being a very true and flush fit.

I returned to the hangar to find my left fillet fully cured. Step number 1 was sanding a smooth transition. I’m happy with the result.

I used flox to join the right side.

And I sanded the remaining empennage fiberglass.

The rear seat back fiberglass top has been waiting completion for some time. Last time, I had sanded and filled what I hoped were the remaining pin holes. I primed it one more time to search for pinholes.

In a previous post I cut the instrument panel cover at an angle. Looking at the way the canopy frame is constructed, this is both impossible, and un-necessary. The canopy frame will provide the function I was after, and as a result, the cover MUST be trimmed flush. I made quick work of trimming with my dremel.

After trimming, I taped the instrument panel. I will file / sand the fiberglass cover to be perfectly flush with the panel.

I also began drilling for the nut plates on the forward section of the cover. I will come back and install the nut plates later.

Time to turn my attention to the fillets. I will do these in stages. The first stage is to join the side fillets to the cover. I will then begin work on the canopy frame. When the canopy frame is further along, I will complete the fillets. This will allow me to incrementally adjust both for optimum fit.

Step number one: tape everything before breaking out the flow and epoxy.

Here is the filet clamped in place with a flox mixture joining the two fiberglass parts.

With that curing, I turned my attention to fitting the right fillet. Its a slow process. Measure, trim, check. Sand, check, sand, check… complete.

I also ran the fiberglass strips for the remaining exposed rivets on the horizontal stabilizer aft of the tip.