The cover in the kit was an unnecessarily large top hat section that robs passenger head clearance under the canopy, so I decided to mould a lower profile carbon fibre cover instead. It needs to partially support passenger body weight at up to 6g, so there needs to be about 4-5 layers, but the low profile, tunnel shape and flanges front and back will make it very stiff and difficult to budge.
I cut part of the wall out of a matching PVC pipe, waxed it and pressed it over the torque tube. With the upper centreline marked, I just layed the pre-wet laminate over the plastic and pinned the front and back edges down with two lengths of RHS steel (radiused edges), which will simultaneously form the flanges. I also need to raise the flap torque tube about 3/16"to accommodate the Oxygen cylinder blister, so I allowed for this by chocking up the pivot blocks at each end with some flat stock. When removed, the PVC pipe will leave at least 1/8" clearance all around the torque tube (which doesn't need to move under g-loads anyway).