Finish Kit

More Drilling Canopy ( 1 hr )

More Canopy drilling completing Step 3, and about half of Step 4 per Sect 38-23.   "Plastic" drill is so dull (by intention for drilling plexiglass) in order to complete holes through aluminum Rail Ass'ly, I've been switching to std #40 bit after drilling through canopy.  Also, at each hole along Aft edge, I'm chamfering each hole to minimize cracking now and when enlarged soon (per advice on VAF forums).

approx 10 remain each side

inside view from approx pilot's eyes (if tall like I am ! )

inside view for much shorter pilot (if at center, too)

Finish Kit

Drilling Canopy ( 4 hrs )

Ready to drill Canopy per Step 9 at 38-22.  Weighted w/ stacks of magazines from recycle pile (cheap, "soft" - just tape around a bundle ) instead of lead or steel weights.   Also used ratchet strap per instructions to initially hold Canopy in position (not very tight so not distorting shape).  Also edges along sides were under minimum of 4.3mm, so added provided shim along Rail.  Prior to locking down final time, I determined I still needed to remove more from rear edge to provide at least 0.8mm spacing to window shim.  Lots of sanding (again!), but finally got it done.
I later came back into shop and drilled "Step 2" #40 size holes starting at top, center along aft edge.  First 14 done.  Yay!

Finish Kit

Canopy Trim to Fit ( 4 hrs )

At Sect 38-21, Steps 8 & 9 marked then chamfered edge of Canopy along 3 inches at "point Oscar" in detail drawing.  Then used fabricated 0.040" thick feeler gauge to locate additional areas along edge to trim/chamfer per Steps 1-4 at Sect 38-22.   Many iterations of mounting Canopy on Frame, then marking again, and filing/sanding some more.  Each time Nancy helped lift Canopy into position.  Eventually achieved good fit along entire front edge and skin.

rotary drum sander works really well for initial passes

Finish Kit

Canopy ( 4 hrs )

Per Sect 38-21, Steps 1-4 located template on Canopy Skin, then positioned Canopy onto Frame Ass'ly for 1st time.    Worked Canopy into best fit alignment and marked centerline in Fwd and Aft areas.  Then in Steps 5-7, marked Aft edge overhang.  Heated garage to 75 deg to minimize chance of cracking.    Removed Canopy and trimmed rear edge using dremel with drum sander (not enough to use cut off wheel) and lots of hand sanding...for couple hours.  Ultimately smoothed edge w/ 400 grit followed by 600 grit sandpaper (smoother than edge as supplied).

 

Finish Kit

Canopy Frame onto Fuselage ( 3 hrs )

Hooray !  Completed Steps 1-7 at Sect 38-19 including bolting on Pin Blocks, riveting Brackets for Micro-switch, and adding 4 Alignment Blocks to Aft Frame.   Lots of details, but went quickly.  Nancy helped lift and guide Canopy Frame Ass'ly onto Fuselage via Hinge Pins.  Per Steps 1-8 Sect 38-20.  Perfect fit & alignment all around - very rewarding.

 

Finish Kit

Canopy Assembly ( 2 hrs )

Completed riveting Rail Assemblies, then riveted Aft Canopy Frame per Steps 2 & 3, Sect 38-18.

Finish Kit

Canopy Frame Assembly ( 4 hrs )

Completed riveting Close Out panel on Canopy Frame, Steps 6-10, Sect 38-17.   Maintained 0.0 degree Twist ..whew !  At Sect 38-18, assembled LH and RH Rail Assemblies and Shim onto Canopy Frame, adding aft fixture.  Riveted most before needing to call it a good day (variety of sizes and reach/clearance meant some trial and error to determine best tool, technique, etc.  Patience paid off with good results)

since original grip was splitting,  used
tennis racquet grip wrap on rivet gun. Sweet !