Monday, May 18, 2009

Drilling the Canopy






Used the painters tape method to determine the canopy tangent line to the canopy frame front bow. It worked OK but used a Sharpie to transfer the line to the tube and then put the canopy on a few more times refining the marks each time. When I was satified, drilled the front bow every 2" using a normal #40 bit.

Before actually drilling the canopy, I went to the hardware store and bought some scrap plexi to practice drilling. I was able to crack the practice piece as the bit exited if too much pressure was used. The key for a FRESH hole -- a plexiglass bit, turning at high speed in a pneumatic drill, using virtually NO pressure. Enlarging an existing hole is going to require a different technique.

Drilled the front bow and rear roll bar alternatively per the plans. Lining up the drill to hit the predrilled hole in the bow was much easier than I thought it would be. Sight it one way, sight again 90 degrees and then make small adjustments till centered.

Then prepped the side skirts and aligned them getting the 1/8" overlap with the side skins to keep out the rain. First match drilled them to the canopy frame and then match drilled them to the canopy and inner angle with the plexiglass bit.

Noticed one problem. The most forward, upper row hole in the side skirt just barely hits the underlying plexiglass. I have 1/2 of a hole on the left side in the plexi (the drill bit wandered) and have a hole as close to the plexi edge as you could imagine on the right side skirt. Compared my results with three other builders and all experienced the same. Was a bit worried but this appears to be a design issue. Sent Van's an e-mail. DO NOT drill these two holes before you mark them and check to see if there is enough plexi behind the hole!!

UPDATE: Sent an e-mail to Van's technical support and they acknowledged that this was a design issue that will be corrected. They gave me the option of leaving the screw out of the left and right side as that area is fully covered and supported by the fiberglass.

Now, looking for advice to do something with the hole very near edge and the partial (1/2 of a hole), right on the edge of the plexiglass canopy.

UPDATE: Will sand both holes to a half-moon shape and smooth all sharp edges. This should eliminate the stress risers and also give me the option of installing the screw and nut.

Canopy Hints Link

Time Today - 6 hours