Finish Kit

Canopy Fairing Fiberglass  ( 5 hrs )

Whew !   Big day doing Sect 38-29 & -30 Steps 10-22 and 1-13.  Needed greater than 4 hrs essentially non-stop doing the fiberglass for the Canopy Fairing (Van's video #3 is super helpful).  The black dye in first resin batch provides opaque layer from inside Canopy just above glareshield.  These were "sandwiched" between layers of static cling to aid final trimming to size,  and especially to hold their shape as transferred from table to Canopy  - worked very well !   Used almost all of the pre-cut strips (various widths) to match the  4" radius template.  Final step was adding the Peel Ply (green nylon material), which will be removed once cured.

used template to insure Ply A's were shaped correctly

infused black dyed resin, then added top layer of static cling

ready to use rotary cutter around templates

top layer peeled off, ready to place on Canopy

adding Ply B, and small filler piece in corner
(per video instructions, this area typically needs some extra)
Ready to add resin.

Play Bs and first narrow strip...ready for resin

Ply C added to B & A...progressively smaller.  
Ready to add resin

shows layers of narrow and wider strips to create 4" radius

Peel Play  ( green nylon material)

Finish Kit

More cutting fiberglass strips ( 2 hrs )

Finished rotary cutting fiberglass using templates for Ply A, B, C, & D, plus Peel Plys for A & D.  Original blade dulled quickly, so went to Wallyworld for replacement - got a Fiskars blade pack and new handle.   Works better, and seems to be lasting longer.

ready to fiberglass next

Using a cutting board helped cutting,
and reduced blade dulling.

Finish Kit

Cutting Fiberglass ( 2 hrs )

Revised forward vinyl tape to accommodate fiberglass template Ply A using xacto knife and great caution !  Then cut 6 pieces of fiberglass at various widths and lengths per list in Step 1, Sect 38-29.  Rotary cutter works really well.

shiny area shows revised line to accommodate Ply A template

other side matching additional area (shiny zone)

after sanding.  Now matches Vans video,
but not clear why original template used
Oct 24 didn't create this exactly

several strips cut to length and width.

Finish Kit

Sanding Canopy "void"  ( 2 hrs )

Sanded void filler per Step 19.  Turned out pretty good (matches example in Van's video).  Cleaned thoroughly with isopropyl alcohol, adding a layer of masking tape along aft edge of Fairing area (will be pulled off with partially cured epoxy in later steps).   Note: I've detected a conflict in masked off area defined by earlier template vs new template for Ply A for fiberglass fabric in next steps.  Noticed first in Van's video their Fairing forward line of tape "widens" quicker as transitions to side of Fuselage.  Checked with new template for Ply A, and seems about 3/8" too narrow for several inches.  Since critical for fiberglass/resin adhesion surface area, planning to rework that portion of black vinyl tape line.  It's right where the filler starts getting wider, so reduces the aluminum surface area for resin adhesion.

from Oct 24 posting:   orig template for forward line. 
Surprised Ply A template conflicts with Ply A template. 
Need about 3/8" forward alum exposed in middle of
transition from top to side

Finish Kit

Canopy Fairing fiberglass (2 hrs )

Nancy (again) helped move Canopy back to bench.  Pleased alignment on Fuselage and on bench is exactly the same...so no twist between either location.  Completed Steps 12-18, Sect 38-28 adding West Systems epoxy resin (105 resin & 206 slow hardener)  w/ microballoons to fill triangular void between top of Canopy Skin and angled edge of Canopy.   Lot's of mixing...adding black tint first, then slowly adding microballoons.  Wearing mask seems important - those microballoons "float" in air like dust if disturbed.  Van's 4 videos on these steps are really helpful.

not all smooth, but will be sanded to
profile anyway.   I mixed a bit "thicker"
with microballoons than needed.

Finish Kit

Canopy Clips, Hinge Covers  ( 4 hrs )

"Tightened" Canopy screws in Zone 2 (along sides) per Sect 38-27, Step 16.   Installed Canopy Clips at 5 locations along front edge ( minimum of 3 may have been sufficient ) per Steps 1-8 Sect 38-28.   Filling the recesses in edge of Canopy for each clip was time consuming.   Finished Hinge Cover Assemblies per Steps 7-15 Sect 38-35.   Little jewels - turned out well w/ double bends in ends forming spring retainers.  [ Note: These are semi-permanent once installed and are meant to easily "give-way" if I ever release the Canopy in flight.   I researched VAF for other builders ideas on how to make them removable for service (to improve access to back side of instruments, etc).  I sent email to one builder who back in March indicated he was considering some alternatives.  For now, I proceeded once I realized they also include foam seal right where I could otherwise devise a pin release, etc.]

ready to start fiberglassing (between black tape)

size 2 rivets are tiny !

formed curved spring retainer at front 

Finish Kit

Hinge Covers, etc  ( 3 hrs )

"Manufactured" two Hinge Covers per Steps 8-10 Sect 38-27.  Prepared 3 Canopy Clips. Created Radius Gauge Template (for transition at leading edge of Canopy).  Nancy helped mount the Canopy ( 1st time with all screws - no clecos ) onto Fuselage.  Fits great.  Added weights (bundled magazines)  again to front area Canopy prepping for next stage -- fiberglass work.

Hinge Covers fitted.

 

Template, Hinge Covers, and 3 Canopy Clips (w/ a blind rivet)