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Date:  8-7-2021
Number of Hours:  4.00
Manual Reference:  18-13CC
Brief Description:  Canopy frame opening cut

This one hurts. My daughter in law is staying with us as she battles some mental health issues. She helped me move the canopy frame today. Within a month she will no longer be with us. I thought she was keen on flying in my plane someday...

The Uli Wolter Cosy Classic plans have you cut the fixed part of the canopy from from the opening part on the plan, and magically miss the longeron. F*&k that. I made a cutting angle guide and cut the frame in the vicinity of the longerons on the workbench with the multitool, opening up to about 1/8" with angle grinder with a 1/16" blade.

Reinstalled the canopy frame on the fuselage, secured with the locating pins forward, (2 each side in the movable portion and 1 in the fixed), and hot glue blocks aft.

Up until now my beautiful plan has gone well, but I continue the initial cut with the multitool, and have a bugger of a time keeping the 45 degrees going. Continue the task with a jigsaw, which works MUCH better, and opened up to a bit less than 1/8" with the angle grinder.

Sanded to an even 1/8" gap with 36g sandpaper glued to thin carbon fibre strips, reinforcing with hot glue blocks as I go.

Transferred frame to workbench, inverted. Adjusted gap at the bottom for an even gap, and glared despariningly at the mess I made in one bit with the multitool.

Built up the drip rail with a variety of materials, the best was some 1/8" coreflute, with taped 1/8" mdf where I needed stiffness.

Wet out 2 x BID on peel ply, and transferred, overlapping forward frame at least 1/2". It wouldn't lay down, so place some more shaped bits of coreflute, weighted for cure.
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Moving frame.

Moving frame.

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Initial cutline

Initial cutline

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