Finish Kit

Canopy Handle ( 1 hr )

Deburred edges and holes, trial assembled Canopy Handle ( Sect 38-14, Steps 1-3 )

Finish Kit

Canopy Rail Ass'ly  ( 4 hrs )

Drilled L & R Side Skins, and Canopy Handles Steps 2- 6 Sect 38-13.  Added Rail Assemblies to Canopy Steps 7-11.  Lots of layers with overlaps - very satisfying to "slide" into position.    Fitting Shims C01411 on each side was a tight fit, but ultimately aligned well. So far, so good with only 0.1 degree twist - if any.

Side Skins

 

Rail Assemblies cleco'd:  note 3 channels
as fixtures insuring correct "spread"

 

Shim added to insure gap for Canopy

Finish Kit

Canopy Rail Ass'ly  ( 3 hrs )

Finished Sect 38-12 steps 8-13,  L & R Canopy Rail Assemblies.  Match drilled #40 holes, deburred, and then riveted.

Finish Kit

Canopy Rail Assembly ( 3 hrs )

Completed Steps 5-7 for Sect 38-12:  building Canopy Rail Assembly.  Deburred, buffed with Scotchbrite, then Primed.  Riveted universal head rivets with shop end in Machined C'sinks on bottom of flange.  This creates good appearance top side, and nearly flush on bottom for the seal to be added later on flange bottom.  Hand bending C01407-L & R Canopy Rails was a new challenge (especially w/in 1/32" of Fuselage side profile), but turned out A-OK.  Just proceeded in small increments.

riveting with "Main Squeeze" mounted to table

bottom view on left, top view on right.

examined curve of Rail.  Starts straight
first 16", then curves as approaches camera

aligned to compare curve in LH to RH sides.   Seems good.

Finish Kit

Van's replaced Aft Canopy Rail Angles ( 2 hrs )

Rec'd Vans replacement stamping C01409-L & -R, Aft Canopy Rail Angles ( 3 days USPS Priority Mail - pretty good).   Bandsawed, ground and deburred new C01409-L (second time ), then flutted per Step 5 in Sect 38-11.  Proceeded with both L & R Angles per Steps 1-3 in Sect 38-12 to drill & machine C'sunk.   Ready to prime then rivet to Canopy Rail Flanges.

Unpacked replacement sent free by Vans. Bend is correct 
vs holes in flanges (matches dwg in instructions - which is 
always a "good thing")  Original Angle in foreground is scrap

Finish Kit

C01409-L ...bum part   ( 3 hrs )

After holiday weekend, back to building.  Discovered C01409-L Angle was incorrectly formed (stamped) by Vans or supplier.  I followed Sect 38-11 instructions to separate LH from RH in single formed part, then ground edges smooth.  Followed Steps 4 & 5 to flute flange until bottom flange was flush to level surface.  But I noticed when lining up C01407-L Rail, it was "off" almost 1/8" from Rail's edge along center...AND it was now bowed along it's length.   I performed same steps for symmetrical RH Angle, and it fit perfectly along Rail, aligning with it's edge as shown in Fig 2.   Side by Side comparison revealed LH Angle has it's bend (stamped shape) at wrong distance from holes.  Sterling at Van's product support checked their inventory, and although he measured 0.015" difference in LH vs RH hole locations from bend, its nowhere near the 0.125" delta on my part.  Assume the metal did not stretch properly, or something slipped in forming.  Van's is mailing a free replacement, and examining what happened in producing those parts, too.  (bummed I spent 1 hr on bandsaw and grinder and another hour resolving - and Van's won't pay to expedite the part to me ).   At least discovered prior to going any further.   So...I worked on other parts such as Sect 38-13 Canopy Handles, and Sects 38-11 Step 6 machine c'sinking Canopy Rail Flange.

correct alignment in foreground on RH parts. Background
shows 1/8" exposure of edge (blue) on Rail ...leading
to flush at each end

LH has too large bottom flange, with too
short of vertical flange cleco'd to Rail

Machine Countersunk specific locations
for 3 and 4 size rivets

canopy handles "done" (started from simple angle

Finish Kit

Canopy Frame ( 3 hrs )

Finished 1/8" drilling on canopy Close Out Panel.   Started Sect 38-11.  Separated RH & LH Canopy Rail Angles via bandsaw, then ground edges smooth.  Fluted (heaviest pieces fluted so far !) LH side. Stopped to go enjoy a beautiful afternoon with mild weather suitable for long ride on my Harley.

done drilling 1/8" (copper clecos) and 3/32" holes (silver clecos).

LH fluted, cleco'd to rail.  RH not done yet.

Finish Kit

Canopy Frame  ( 3 hrs )

Cont'd Sect 38-10 at Steps 3 to 12.  Added Close Out Panel, then Support Flanges.   Taking extra time to frequently measure w/ digital scale (accurate to 0.1 deg) the LH and RH sides to insure NO TWIST.  Holding to within 0.1 degree.  As progressed, stabilized and held even closer to 0 deg difference.   Drilled 3/32" holes (later enlarge to #40), match drilling into flanges in many locations.  Drilled 1/8" holes (later enlarge to #30), match drilling several locations on forward frame flanges.  Tricky pattern of 1/8 vs 3/32, so marked on panel to insure follow instructions (also drilled 3/32" first, so if make error, I can enlarge to 1/8)

close out panel being cleco'd from center

fit great, aligned really well

Measured each side many times as progressed (here 7.0 deg)
to insure no more than 0.1 deg difference one side to other.

added Support Flanges to rear portion

Added Support Flange (to right in pic)

drilled marked 3/32 holes, started 1/8" (marked so avoid Oh-- #$@%& !)
Part way done with 1/8 ...so far so good.