Fitting the Canopy
Posted: Sat Nov 09, 2024 9:34 amHi all,
I finally got to a point where it was time to fit the canopy to the plane. AND... a warm enough day where I didn't have to worry about cracking it. OK.... I've watched all the vids I could find, including ones from the Vans people. I've seen a bunch of guys using Oscillating tools... but it looked slow, and the vibration could be bad. Then I watched guys using cut-off wheels. That was everything from a small Dremel tool, up to a 4" angle grinder. That group seems to think that the partial melting is better than leaving deep scratches, and may help prevent cracks. (don't know) I wasn't a fan of the band saw method that Sonex says to use.... but after consideration... I thought maybe it would be the best. The obvious downside is... you NEED a helper that can follow your lead. My only change to what Sonex tells us is that I used a less aggressive blade. Sonex says to use a 6-8tpi blade. I used a 14tpi. I did this because I saw one post saying the course blade was chipping if the Plexi came up off the table. The 14tpi didn't have that issue. And..... the band saw cuts like butter. It will go as fast, or as slow as you want.
Since my canopy has been sitting around, I tried to peel up the old tape, but it just made a mess. (Adhesive was sticky) Eventually, I was able to mark new lines, and I cut the front and back first. I followed up with a block sanding to take of any rough edges. A check fit was done... and a second set of tape markings was put on, and a Second cut was done.
At this point, I was close. I knew I wanted to "Sand" to get a final fit. I wound up using an angle grinder, with a warn flap disk on it. It would remove material quick, but with a light hand, it would leave a nice finish. FYI.... finishing with this method leaves no harsh edge lines... but it makes a mess, and all the dist is staticky. (Had to shower when I was done LOL) Oh... don't forget, you will need a little gap after it's installed. so don't make it too tight.
I would recommend using the Bandsaw, and an agressing sander... and getting a helper regardless of the method you use. Since you will be taking it on and off A LOT.... it's just easier that way. In the next few days, I'll get the frame and plexi drilled. (pictures are in reverse order for some reason. Sorry)
I finally got to a point where it was time to fit the canopy to the plane. AND... a warm enough day where I didn't have to worry about cracking it. OK.... I've watched all the vids I could find, including ones from the Vans people. I've seen a bunch of guys using Oscillating tools... but it looked slow, and the vibration could be bad. Then I watched guys using cut-off wheels. That was everything from a small Dremel tool, up to a 4" angle grinder. That group seems to think that the partial melting is better than leaving deep scratches, and may help prevent cracks. (don't know) I wasn't a fan of the band saw method that Sonex says to use.... but after consideration... I thought maybe it would be the best. The obvious downside is... you NEED a helper that can follow your lead. My only change to what Sonex tells us is that I used a less aggressive blade. Sonex says to use a 6-8tpi blade. I used a 14tpi. I did this because I saw one post saying the course blade was chipping if the Plexi came up off the table. The 14tpi didn't have that issue. And..... the band saw cuts like butter. It will go as fast, or as slow as you want.
Since my canopy has been sitting around, I tried to peel up the old tape, but it just made a mess. (Adhesive was sticky) Eventually, I was able to mark new lines, and I cut the front and back first. I followed up with a block sanding to take of any rough edges. A check fit was done... and a second set of tape markings was put on, and a Second cut was done.
At this point, I was close. I knew I wanted to "Sand" to get a final fit. I wound up using an angle grinder, with a warn flap disk on it. It would remove material quick, but with a light hand, it would leave a nice finish. FYI.... finishing with this method leaves no harsh edge lines... but it makes a mess, and all the dist is staticky. (Had to shower when I was done LOL) Oh... don't forget, you will need a little gap after it's installed. so don't make it too tight.
I would recommend using the Bandsaw, and an agressing sander... and getting a helper regardless of the method you use. Since you will be taking it on and off A LOT.... it's just easier that way. In the next few days, I'll get the frame and plexi drilled. (pictures are in reverse order for some reason. Sorry)
