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)

Finish Kit

Canopy Wear Strips  ( 4 hrs )

Per Sect 38-26 Steps 16 and 18, assembled fasteners along Canopy Aft Frame, capturing Seat Retainer.   Tightened carefully to not stress Canopy - per Van's Builder Support (they clarified to only tighten to remove "free play", such can still turn screw heads - to minimize stress on plexiglass).    Per Steps 1-7, Sect 38-27 built LH and RH Wear Strips from a UHMW strip.  Sanded to shape, match drilled to Side Skin, machine c'sunk for shop ends of rivets, then set rivets.  Looking good !

Screw heads flush along Aft Frame

White wear strip shaped & rivet 

Finish Kit

Canopy Handles, Seal notched ( 4 hrs )

Completed Step 9, riveting Side Skin, then riveted on LH & RH Canopy Handles.   Some challenges getting bucking bar into position, especially trying to avoid marring interior paint.   For one rivet, took me third time (aaargh !) to get it just right - but I'm getting good at drilling out rivets to replace.  Deburred two Seal Retainers (edges and holes per usual), then per Steps 11 -13 used to mark locations to notch Seal (clearance to fasteners on Aft Frame).  Instructions recommend a paper punch to put radii on notch corners, but mine wasn't cooperating.  So I sharpened the end of  a scrap tube which worked perfectly.

nice aerodynamic shape ! for Canopy Handles

notching seal

Finish Kit

Riveting Canopy Side Skins ( 4 hrs )

Determined needed a few thousands deeper C'sinks along several locations on RH Side Rail for Skin to be uniform and tight at top edge along Canopy.  Then I could add machine screws and nuts along LH & RH Rails - loosely per instructions.   I've substituted 6 lobe (Torx) SS screws instead of the provided SS Phillips head screws (per Carl and Rafael's example RV14a build).   Far less "stripping" of heads, and they look cool too.  here's source   Next riveted Side Skins, completing RH side and most of LH side.   Looking really good !

wrapped edges of bucking bar w/ tape,  but still some marking on fresh interior paint.   I'll have to mask and touch up spray...